Gear Drive 91

Chapter 5
GEAR DRIVE
https://www.cs.cmu.edu/~rapidproto/mechanisms/chpt7.html

This chapter consists of two parts:

Part 1: Geometrical parameters and forces acting on the shaft;
Part 2: Design and Checking Calculation.
Nội dung chương này gồm 2 phần:
Phần 1: Các thông số hình học và lực tác dụng;
Phần 2: Tính toán thiết kế và kiểm nghiệm.

PART 1: GEOMETRICAL PARAMETERS AND FORCES ACTING ON THE

SHAFT;
Example 5.1 The spur gear drive has a modulus m = 10 mm, number of teeth z1 =
18 and z2 = 47. The gears are uncorrected . Calculate the geometry parameters in the
case of internal and external toothing.
Solutions:
1) External gearing
Pitch diameter of driving gear:
d1 = mz1 = 10.18 = 180 mm
Outside diameter of driving gear:
da1 = m(z1 + 2)
da1 = 10(18 + 2) = 200 mm
Root diameter of driving gear:
df1 = m(z1 – 2,5) = 10(18 – 2,5) = 155 mm
Pitch diameter of driven gear:
d2 = mz2 = 10.47 = 470 mm
Outside diameter of driven gear:
da2 = m(z2 + 2)
da2 = 10(47 + 2) = 490 mm
Root diameter of driven gear:
92 Chapter 5

df2 = m(z2 – 2,5) = 10(47 – 2,5) = 445 mm

Center distance:
m(z2  z1 ) 10(47  18)
aw  
2 2
a w  325 mm.

2) Internal gearing
The same as external gearing parameters, except da2, aw and df2.
Outside diameter of driven gear:
da2 = m(z2 - 2)
da2 = 10(47 - 2) = 450 mm
Center distance:
m(z2  z1 ) 10(47  18)
aw  
2 2
a w  145 mm

Root diameter of driven gear:

df2 = 2aw + da1 + 0,5m = 2.145 + 200 + 0,5.10 = 495 mm.

Table 6.2 Geometry parameters

Formula
Parameters
non correction Value
m(z 2  z1)
Axle base (Center distance) aw = a =
2 cos 
Addendum modification
Whole depth h = 2,25m
Radial clerance c = 0,25m
Fillet radius  = m/3, where m is module
Pitch diameter d1 = mz1/cos; d2 = mz2/cos
Diameter of the initial circles
dw1 = d1; dw2 = d2
(Rolling circle diameter)
Base diameter db = d cosα
Outside (Tip) diameter
- External gearing da1 = d1 + 2m
da2 = d2 + 2m
- Internal gearing d a1 = d1 + 2m
da2 = d2 – 2m
Root diameter
- External gearing df1 = d1 – 2,5m
df2 = d2 – 2,5m
- Internal gearing df2  2aw + da1 + 0,5m
Angle:
- Normal pressure angle  = 20o (14.5, 17.5, 20, 22.5, 25, 30)
Gear Drive 93

tantw = tant = tan

- Helical gear
cos 
- Straight spur gear tw = t = 

Example 5.2 The spur gear drive has a center distance of a = 710 mm, number of
teeth z1 = 24 and z 2 = 151. The gears are uncorrected. Choose the helix angle ,
the normal modulus m and the equivalent number of teeth.
Solutions:
Relationships between center distance aw, helix angle  and normal module m:
m(z1  z2 )
aw 
2 cos 
From here we deduce:
m(z1  z2 ) m(24  151)
cos   
2a w 2.710

For helical spur gear transmission:

20o    8o

therefore: cos 8o  cos   cos 20o

m(24  151)
so: cos 8o   cos 20o
2.710

2.710 cos 8o
 m  7, 62
24  151
8, 04  m  7, 62

According to the standard value, we choose m = 8 mm.

According to the value of m = 8 mm, we can calculate  = 9,62o.
Example 5.7 Determine the geometrical parameters of the spur gear pair, knowing that
z1 = 24, number of revolutions n1 = 1200 rpm, n2 = 480 rpm, center distance aw = 250
mm, modulus m = 5.5 mm, the ratio of width to diameter bd = 0.8.
Solutions:
1) Determine the gear speed ratio:
n1 1200
u   2, 5 .
n2 480
2) Number of teeth of driving gear (pinion):
94 Chapter 5

z2 = z1u = 24.2,5 = 60.

3) Determine the helix angle:
mn (z1  z2 ) 5, 5(24  60)
cos     0, 924
2a 2.250

Therefore:   22, 48o .

4) Determine the pitch diameters:
mn z1 24.5, 5
d1    142, 86 mm
cos  0, 924
mn z2 60.5, 5
d2    357,14 mm
cos  0, 924
- The tip (outside) diameters::

d a1  d1  2mn h*a  142, 86  2.5, 5.1  153, 86 mm

d a 2  d 2  2mn h*a  357,14  2.5, 5.1  368,14 mm.

As standard, tooth height coefficient (addendum) ha* = 1, radial clearance

coefficient c* = 0,25.
5) Face width:
bw = bdd1 = 0,8.142,857 = 115 mm.
6) Determine the length of the common normal:
W = [(zn – 0,5) + z1 invt]mcos
where: zn - number of teeth in common normal

z  tan  x 
zn  1   inv t   0, 5
  cos b
2 

z1 cos  t
with: cos  x   cos  t
z1  2x cos 

tan  tan 20o

tan  t    0, 3939
cos  0, 924

 t  21, 5o suy ra : cos  x  cos  t  0, 9304

sin b  sin . cos   sin 2,1o. cos 20o

 0, 3824.0, 9397  0, 3593
Gear Drive 95

Therefore: b  21, 05o ; cos b  0, 9332

inv t  inv21, 5o  0, 018665

From here we deduce:

24  0, 3939 
zn    0, 018665   0, 5  3, 81
3,14  0, 93322 

select zn = 4 and the length of the common normal:
W = [3,14(4 – 0,5) + 24.0,018665] 5,5.0,9397 = 59,12 mm

Therefore, the condition:

bw 115
W   350, 4 mm is satisfied.
sin  0, 3282
Example 5.8 The spur gear transmission has a normal modulus m and an helix angle
. The front contact ratio  = 1.2. Determine the width b of the gear so that there are
always at least two (three, four, ..., n) pairs of teeth in the engagement zone?
Solutions:


b

x
Ñieåm cuoái
g = 
 pt
vuøng aên khôùp
2pt

Ñieåm ñaàu vuøng aên khôùp

Figure 5.2
96 Chapter 5

1) 1) According to figure 5.2, in order to have at least two pairs of teeth on the gear
engagement area, then:
g  x

where g is the length of the engagement on the engagement line (which is the
distance between the intersection of the engagement line and the tip (outside) circles of
the driving and driven gears).
 p
g    p t   n
cos 

The distance x is determined by the formula: x  2p t  b tan .

2) From here infer:
 p t  2p t  b tan 
b tan   p t  2   

p t  2    .m  2   
b   .
tan  sin 
3) In the general case, in order to have n pairs of teeth engaged in the gear-pair
engagement area (contact line):
.m  n   
b  .
sin 
FORCES ACTING ON THE GEARS
Example 5.9 The gears of the transmission system are as shown in figure 5.3
(transmission from 1 to 6). Given T1 = 100 Nm, the bevel gear modulus, the helical
gear modulus m and the straight spur gear modulus m have the same value and
equal to 4 mm, number of teeth z1 = 20, z2 = 40, z3 = 20, z4 = 60, z5 = 28, z6 = 56.
Determine:
a) Helix angle  so that shafts II and IV are concentric.
b) Analysis of the force acting on the gear pairs.
c) Values of these forces.
II III

Solutions:
a) For the centerlines of shafts II
and IV to be concentric, then a34 = a56

IV

Figure 5.3
Gear Drive 97

on the other hand:

m(z3  z4 ) m(z5  z6 )
a 34  ; a56 
2 cos  2

m(z3  z4 ) m(z5  z6 )
So:  Fr 1
2 cos  2 Ft 1

m(z3  z4 ) 80 Fa 1
o
  arccos + arccos  17, 75
m(z5  z6I ) 84

b) Analysis of forces acting on gears (Figure.5.4)

II

+
Fr 2

Ft 2 Fa3
Ft 3
Fa2

Fr 3
a) b)

III
+

Fr 4

Ft 4 Fa4
Fr 5

c) d) Ft
5

F 5.4 Forces acting on gears

Peripheral load:
+

Ft 6
2T1 .103 2T1 .103
Ft1  
d m1 mm z1 Fr 6

where: mm = me (1 – 0,5be) = 4(1 – 0,5.0,285) = 3,43 mm

IV
3
2.100.10
therefore: Ft1   2915 N
3, 43.20
98 Chapter 5

Fr1  Ft1 tan  cos 1  2915. tan 20o. cos 26, 57o  948, 9 N

1 z 1
where: 1  arctan  arc tan 1  arct an  26, 57o
u1 z2 2

Fa1  Ft1 tan  sin 1  2915. tan 20o sin 26, 57o  474, 6 N

Value of forces acting on bevel gear 2:

Ft2  Ft1  2615 N

Fr2  Fa1  474, 6 N

Fa2  Fr1  948, 9 N

- Forces acting on helical gear 3 and 4

Torque acting on the shaft II:
T2 = T1u1 = 100.2 = 200 Nm
Values of forces acting on teeth of gear 3:

2T2 .103 2 cos T2 .103 2. cos 17, 75.200.103

Ft   
3 d3 mz3 4.20

Ft3 tan  4762. tan 20

Fr3    1819, 9 N
cos  cos17, 75

Fa3  Ft3 tan   4762 tan 17, 75  1524, 3 N

Forces acting on helical gear 4:

Ft4  Ft3  4762

Fa4  Fa3  1524, 3 N

T3  T2 . u 2  600 Nm

Values of forces acting on teeth of gears 5:

2T3 .103 2T3 .103 2.600.103

Ft5     10714, 3 N
d5 mz5 4.28

Fr  Ft tan   10714, 3. tan 20  3900 N

5 5

Forces acting on teeth of gears 6:

Gear Drive 99

Ft6  Ft5  10714, 3 N

Fr6  Fr5  3900 N

Example 5.10 Transmission power and number of revolutions on input shaft (hight
speed) coaxial double-stage reducer (Fig.5.5) P = 5 kW, n = 500 rpm. The gear ratio of
the 1-2 helical spur gear pair is u12 = 4, the 3-4 straight gear pair u34 = 5. The gears
are uncorrected. The modulus of all gears have the same value of 4 mm. Request:
a) Given the center distance a = 240 mm, determine the number of teeth z1, z2, z3, z4
and the tooth helix angle with 20o ≥  ≥ 8o.
b) Analyze the direction and determine the value of the forces acting on the gears.

Figure 5.5
Solutions:
a) Number of teeth z1, z2, z3, z4 and helix angle:
- Number of teeth z1, z2 and helix angle:
From the condition 20o    8o
we deduce:

2a w cos 8o 2a w cos 20o

 z1 
m(u  1) m(u  1)

2.240 cos 8o 2.240 cos 20o

 z1 
4(4  1) 4(4  1)

and: 23,77  z1  22,55

We choose z1 = 23 teeth, number of teeth of driven gear:
z2 = 23.4 = 92 teeth
- Helix angle:
100 Chapter 5

m  z1  z2 
  arccos
2a w
4(23  92)
  arccos  16, 6o
2.240
- Number of teeth z3, z4

Center distance:

mz3 (u 34  1)
aw 
2
Substitute values:

4z3 (5  1)
240 
2
we infer: z3 = 20 răng
and z4 = z3u34 = 20.5 = 100 răng

b) Directions and values of forces acting on gears (Fig.5.6)

Fig 5.6
Gear Drive 101

Torque acting an shaft I:

9550P1 9550.5
T1    95, 5 Nm
n1 500
Diameters of gears:

4.92
dt2 = mtz2 =  384 mm
cos 16, 6
d3 = mz3 = 4.20 = 80 mm
- Forces acting on gears 1 and 2:

2T1 2. cos .T1

Ft1  Ft2  
d t1 mn z1
2. cos 16, 6.95500
  1989, 6 N
4.23

2T1 .103 2T1 .103 cos 

Ft1  Ft2  
d t1 mz1

2.9550.103. cos16, 6
  1989, 6 N
4.23
Fa1  Fa2  Ft1 tan   1989, 6 tan 16, 6
Fa1  Fa2  593,1 N
Torque acting an shaft II:
T3  T2 . u12  95, 5.4  3820 Nm `

- Forces acting on gears 3 and 4:

2T2 .103 2T2 .103 2.3820.103

Ft3     9550 N
d3 mz3 4.20
Fr3  Ft3 tan   9550 tan 20
Fr3  3475, 9N  Fr4 .

EXERCISE
Geometry parameters of spur gear
Exercise 5.11 Number of teeth driving gear z1 = 21 teeth, outside diameter of
driving gear da1 = 126.5 mm. Determine the modulus m, knowing that the
addendum is equal to the modulus (ha = m).
102 Chapter 5

Exercise 5.13 The helical spur gear transmission has a center distance a = 940 mm,
m = 16 mm. The gears are uncorrected , gear drive speed ratio u = 5. Determine
number of teeth z1, z2 and helix angle β (20o    8o for helical spur gear).
Solutions:
For helical spur gear - Helix angle:

20o    8o

cos 8o  cos   cos 20o

aw = (dt1+dt2/2= mt (z1+z2)/2 = m (z1+z2)/(2cos β)

from here: cos β= m (z1+z2)/2aw= mz1(u +1)/2aw
m(z1  z2 ) mz1 (u  1)
Therefore : cos 8o    cos 20o
2.a w 2.a w

m(z1  z2 ) mz1 (u  1)
cos 8o    cos 20o
2.a w 2.a w

2.a w cos 8o 2.a w cos 20o

 z1 
m(u  1) m(u  1)

2.940. cos 8o 2.940. cos 20o

 z1 
16(5  1) 16(5  1)

2.940. cos 8o 2.940. cos 20o

 19.4  z1   18.4
16(5  1) 16(5  1)
z1 = 19, z2 = uz1 = 5.19= 95 teeth

cos β= 16.19 (5+1)/2.940 from here β = 14.07 0

Geometry parameters of bevel gear

Exercise 5.16 In bevel gear transmission with gear ratio u = 1, number of teeth z1
= 25. External cone distance calculated by contact strength Re  210 mm. Calculate
the large end module me and outside pitch diameter (at large end) de, indicating the
maximum addendum (at large end) hae1 equal to the large end module me.

de1
Re = = 0,5me z12  z22 =0.5* me * z1 2
2 sin1
Gear Drive 103

me = Re/(0.5* 25 2 )= 11.87 mm
choose me = 12mm. de1 =me.z1 = 300mm

Exercise 5.17 For a straight tooth bevel (cone) gear drive that transmits between
two orthogonal intersect shafts. Indicates: the large end module me = 4 mm, the
number of teeth of the drinving gear z1 = 20 teeth, the driven gear z2 = 40 teeth, the
ratio be = 0.3.
a) Calculate the pitch (rolling) cone angle 1, 2.
b) Calculate the modulus, pitch diameter and number of teeth of the equivalent spur
gear of the driving gear.

Exercise 5.18 Straight bevel gear drive has known geometric parameters: mean pitch
modulus mm = 6 mm, face width b = 75 mm, number of gear teeth z1 = 25, z2 = 50.
Determine:
a) The pitch angle 1, 2.
b) Outer pitch modulus me.
Exercise 5.22 For the drive system as shown in Figure 5.7.
a) Determine the direction of the forces acting on the gear pairs.
b) How does the change direction of I shaft rotation affect the results of calculation and
design of machine elements?

Truc I
1
5
3
Truc II

1
2

Truc III Truc IV

4 6

Figure 5.7
Analyze and determine the value of the force acting on the shafts
Exercise 5.25 Determine the direction and value of the forces acting on the gear pairs
according to the diagram in Figure 5.8. Given the following data in advance: T1 = 80
Nm, z1 = 20, z2 = 40, z3 = 18, z4 = 54 (on figure 5.8a then z1 = z3 v z2 = z4). The
modulus of all gear pairs is the same m = 4 mm (for bevel gears me = 4 mm). Helix
104 Chapter 5

angle: herringbone V gear is 30o, helical gears is 10o. The pressure angle of gear pairs
 = 20o.

Figure 5.8
Exercise 5.26 The transmission system transmits the motion from the motor to the V-
belt drive, the double stage reducer, the open bevel gear drive, the chain drive and then
to the working part with the above data. figure 5.9.
a) Determine the number of rotations of the working part.
b) Analysis of the force acting on the shafts I, II, III, IV.
c) When changing the direction of rotation of the motor shaft, how does the direction
of the forces acting on the gear pairs 1-2 and 5-6 change?
Gear Drive 105

Figure 5.9
Exercise 5.27 Tránmission system as shown in Figure 5.10 with 1, 2 – bevel gear with
outside pitch module me 3, 4 and 5, 6 – helical spur gear pairs with module m.
Indicates the number of motor revolutions nm = 1440 rpm, torque acting on shaft I TI =
120 Nm. Number of gear teeth: z1 = 20, z2 = 40, z3 = 24, z4 = 72, gear speed ratio 5-6:
u56 = 2, transmission ratio of two chain drives are the same uch = 2.5 , belt drive speed
ratio ub = 2. Module of gear pairs m = me = 4. Pressure angle  = 20o. Identify:
a) Helix angle 1 so that a = 200 mm.
b) Number of teeth z5, z6 and helix angle 2 so that centerline of shafts III and IV are
concentric, knowing that 20o  2  8o.
c) The number of revolutions of the shafts V and VI.
d) Direction and value of forces acting on the gears.
106 Chapter 5

Truïc coâng
taùc VI
Truïc IV
Truïc II
Truïc I

Truïc III
Truïc coâng
taùc V

Ñoäng cô

Figure 5.10

Example 5.28 Transmission system as shown in Figure 5.11 (transmission from

shaft I to shaft II, III and shaft IV to mixing tank with 1, 2 – straight bevel gear with
module me; 3, 4 - heringbone gears has a module m; 5, 6 - spur gear has a module m.
Show that the number of revolutions of shaft I is n I = 985 rpm and torque T I = 53.3
Nm. Number of teeth of gears: z 1 = 18 , z2 = 36, z5 = 20, z6 = 60, gear ratio u34 =
z4/z3 = 3,15, chain drive speed ratio ux = 2. Determine:
a) The number of revolutions of the mixing tank shaft.
b) Direction of forces acting on axis II.
c) Torque on the mixing tank, assuming a transmission system efficiency of 1.
Gear Drive 107

Truïc IV

Truïc III

Thuøng troän Truïc II

Truïc I

Ñoäng Cô

Figure 5.11
PART 2 DESIGN AND CHECK CALCULATION -
EXAMPLE WITH SOLUTION Allowable stress, load capacity
Exercise 5.45 Calculation and design of single-stage heringbone V-gear reducer
(H.5.26) knowing that the power on the driving gear P 1 = 18 kW, the number of
revolutions of the driving gear n1 = 1000 vg/min, the driven gear n 2 = 250 vg/min,
load changing continuously with heavy load mode,
working without reversing. Working time La = 3 years,
working 300 days per year, working 2 shifts 1 day. The
driving gear material is 40CrNi, b = 932 MPa, H1 = 270
HB; driven gear material is 40Cr steel, b = 932 MPa, H2
= 260 HB.

Solutions: Figure 5.26

1) Speed ratio:
n1 1000
u   4.
n2 250
2) Determine the total number of equivalent duty cycles:
Total working time in hours:
Lh = 3.300.24.2/3 = 14400 giờ
108 Chapter 5

For driven gear:

N1 = 60n1Lh = 60.1000.14400 = 8,64.108 chu kỳ
NHE1 = N1KHE = 8,64.108.0,5 = 4,32.108 chu kỳ
The factor KHE with heavy load is valuable 0,5 [10].
For driving gear:

NHE1 8, 64.108
N 2    2,16.108 cycles
u 4
NHE2  N 2 .K HE  2,16.108.0, 5  1, 08.108 cycles

3) Determination of the allowable contact stress and bending stress

- Contact fatigue limit for driving gear:
oHlim1 = 24 HB + 70 = 2.270 + 70 = 610 MPa
- For driven gear:
oHlim2 = 24 HB + 70 = 2.260 + 70 = 580 MPa
- Safety factor: SH1 = SH2 = 1,1.
- Base number of cycles NH0:
NHO1 = 30HB12,4 = 30.2702,4 = 2,05.107
NHO2 = 30HB22,4 = 30.2602,4 = 1,87.107
because: NHE1 = 4,32.108 > NHO1 = 2,05.107, do that KHL1 = 1
NHE2 = 1,08.108 > NHO2 = 1,87.107, do that KHL2 = 1
Therefore, the allowable contact stress for the driving gear:
oH lim1 .0, 9 610.0, 9
H 1  K HL1  .1  499,1 MPa
sH1 1,1
For driven gear:
oH lim 2 .0, 9 580.0, 9
H 2  .K HL2  .1  474, 5 MPa
sH2 1,1
- Selectable allowable contact stress:

[H] = 0,45([H]1 + [H]2) = 0,45(499,1 + 474,5) = 438,1 MPa

Because [H] = 438,1 < [Hmin] = [H]1 = 474,5 MPa

We choose [H] = 474,5 MPa
- The allowable bending stress can be preliminarily determined by the formula:
Gear Drive 109

oF lim1
F1   K FCK FL
sF

where: oF lim1  260  HB1  260  270  530 MPa

oF lim 2  260  HB2  260  260  520 MPa

Select safety factor sF1 = sF2 = 2.
Factor KFc = 1 due to one-way work.
Life factor KFL1 = KFL2 = 1 because:

NFE1 = N1.KFE = 8,64.108.0,3 = 2,592.108 > NFO = 5.106

NFE2 = N2.KFE = 2,16.108.0,3 = 0,648.108 > NFO = 5.106

530
We choose:  F  1  .1.1  265 MPa
2
520
 F  2  .1.1  260 MPa.
2
4) Determine the torque on the driving gear:
9550P1 9550.18
T1    171, 9 Nm
n1 1000
Center distance aw:

T1K H
a w  430  u  1 3
2
 ba  H  u

Ratio between facewidth and center distance ba = 0,4

 ba  u  1 0, 4.5
From here infer:  bd    1, 0
2 2
According to table 6.4 [10], we choose KH = 1,08.

171, 9 .1, 08
Therefore: a w  430(4  1) 3  172, 3 mm
0, 4 . 474, 52 . 4
According to the standard serie, we choose aw = 180 mm.
Module m = (0,01 ... 0,02) aw, according to the standard we choose m = 3 mm.
5) Geometry parameters of gear drive:
110 Chapter 5

mz1 (u  1)
aw  because 40o    30o
2 cos 
mz1 (u  1)
From here infer: cos 30o   cos 40o
2a w

2a w cos 30o 2a w cos 40o

or  z1 
m(u  1) m(u  1)

20,78  z1  18,33
We choose z1 = 20 teeth, and have :
3.20(4  1)
cos    0, 8333
2.180
 = 33,56o
b
Ratio between facewidth and center distance  ba   0, 4
aw
Therefore: b = 0,4 aw = 0,4.180 = 72 mm
Number of teeth of driven gear z2 = z1u = 20.4 = 80 răng
Then we check the gear drive according to the bending and contact strength.

Exercise 5.46 Calculation of double-stage coaxial reducer (Figure 5.27a) with

transmission power P1 = 11 kW, n1 = 960 rpm. The gear speed ratio of high speed
helical gear pair is u1 = 4, the pair of slow speed straight spur gear u2 = 3. The
gears are uncorrected . The load varies as shown in Figure 5.27b. The reducer
works 300 days per year and working life is 10 years. The working factor for the
day is 0.66. Gear material is 40 Cr steel.
Gear Drive 111

T T

0,75T

0,2T

t
0,2t 0,5t 0,3t

Chu kyø t

a) b)
Figure 5.27

BEVEL GEAR
Exercise 5.47 Determine the torque that the closed bevel gear transmission can
transmit with the sum of the bevel angles divided 1 + 2 = 90o from calculating the
teeth according to the contact and bending stresses. Given in advance: outer pitch
modulus = 5 mm, number of teeth z1 = 20, z2 = 40, rotationals speed of driving
gear n1 = 540 rpm, material is normalized 50Mn steel, b = 549 MPa , H1 = 180 ...
230 HB. The transmitter works non-reversing. Constant load, working time Lh =
10000 hours.

Example 5.48 The straight bevel gear transmission (H.5.28) works 3 shifts a day for 4
years, the load varies shown in Fig. 5.30a. Design calculation the bevel gear according
to the given data: torque on the driven gear T2 = 40 Nm, gear width coefficient b =
0.3, number of revolutions on the driving gear n1 = 740 rpm, driven n2 = 375 rpm.
112 Chapter 5

Figure 5.28
Solutions:
1) Select the driving gear material is structural improvement C45 steel, hardness
230 HB, driven gear material - normalized C45 steel, hardness 210 HB (choose
according to the average value of the above steels).
2) Determine the equivalent number of cycles NHE and life factor K L:
- Drinving gear (Pinion):
3
 T 
NHE1  60 c  i  n i t i
 Tmax 
 60.1.740((0, 53.0,1  13 . 0,1  0, 53 . 0,1)L h

 60.1.740.0,125.35040  1, 9.108 chu kyø

where: Lh - total working time in hours
Lh = 4.365.24 = 35040 h
The number of cycles to the inflection of the fatigue curve NHO:

NHO1  30 HB2,4 = 30.2302,4 = 1,4.107 chu kỳ

NHO1
because, NHE1  NHO1 , therefore K HL1  6  1
NHE1

- Driven gear (Wheel):

Gear Drive 113

NHE  60.1.375.(0, 53.0,1  13.0,1  0, 53.0,1).35040

2

 9, 86.107 cycles

NHO2  30 HB2,4  30.2102,4  1,12.107 chu kyø

because, NHE  NHO therefore K HL  1.

2 2 2

3) Determination of allowable contact stress:

oH lim1 . 0, 9 530 . 0, 9
[H ]1  K HL1  .1  434 MPa
sH 1,1
oH lim 2 . 0, 9 490.0, 9
[H ]2  K HL1  .1  401 MPa
sH 1,1

where: oH lim1 , oH lim 2 - fatigue contact limits of pinion and wheel

oH lim1  2HB1  70  2 . 230  70  530 MPa

oH lim 2  2HB2  70  2 . 210  70  490 MPa
sH - factor of safety, for normalized and structural improvement steel sH = 1,1.
For straight bevel gears, the allowable contact stress when calculating is selected
according to the smallest value from two value [H]1 và [H]2, therefore [H] = [H]2 =
401 MPa.
4) Allowable bending stress:
F lim K FL . YR . Yx . Y . K FC
[F ] 
sF

Since the coefficients YX, Y, YR in the preliminary design stage have not been
determined, the above formula can be written in the form
oF lim K FC
[F ]  . K FL
sF

Fatigue bending limits Flim for normalized and structural improvement steel:
Flim1 = 1,75HB1 = 1,75.230 = 402,5 MPa
Flim2 = 1,75HB2 = 1,75.210 = 367,5 MPa
Safety factor for bengding stress sF = 1,8.
Factor taking into account the effect of reverse operation FFC = 0,75.
Number of equivalent cycles to the driving gear (pinion):
114 Chapter 5

6
 T 
NFE1  60c  i  n i Ti
 Tmax 
 60.1.740.(0, 56.0,1  16 . 0,1  0, 56 . 0,1).35040

 1, 6 .109

Because NFE1  5.106 therefore K FL1  1.

Number of equivalent cycles to the driven gear (wheel):

NFE2  60.1.375(0, 56.0,1  16.0,1  0, 56.0,1)35040  7, 9.108

Because NFE  5.106 therefore K FL  1

2 2

Thay thế các giá trị vừa tìm được vào công thức xác định [F], ta có:
402, 5 . 0, 75
[F ]1  .1  172, 5 MPa
1, 75
367, 5 . 0, 75
[F ]2  .1  157, 5 MPa.
1, 75
5) Speed ratio:
n1 740
u    1, 975.
n2 375

6) The outside pitch diameter for driven gear:

T1K H
d e2  9503
0, 85(1  0, 5 be )2  beu[H ]2

T2K H

0, 85(1  0, 5 be )2 u 2 [H ]2  be

40 .1, 3
 9503  72, 8 mm
0, 85(1  0, 5 . 0, 3)2 .1, 9752 . 4012 . 0, 3

7) From table 6.19 [10], we choose z1p = 25 teeth, hardness HB1 and HB2 less
then 350 HB, so z1 = 1,6z1p = 1,6.2,5 = 40 teeth.

8) Number of teeth of driving gear z2 = z1.u = 40.1,975 = 79 teeth.

9) Module of outside pitch diameter:
Gear Drive 115

de1 72, 8
me    1, 82
z1 40
From standard serie, we choose me = 2, and:
d e1  me . z1  2 . 40  80 mm.
10) outside pitch diameter of driven gear:
d e2  me . z2  2 .79  158 mm.
11) Cone distance:

Re  0, 5me z12  z22  0, 5 . 2 402  792  88, 5 mm.

12) Face width:
b = be . Re = 0,3.88,5 = 26,55 mm.
13) Pitch angles:
1 1
1  arctan  arctan  26, 85o
u 1, 975

2  90o  26, 55o  63,15o.

14) Average pitch diameter :
 25 
d m1  d e1 1  0, 5 be   80  1  0, 5  67, 8 mm
 88, 5 
 25 
d m2  158  1  0, 5  135, 7 mm.
 88, 5 
15) Peripheral velocity:
d m1 n1  . 68, 7 .740
v    2, 66 m/s.
60000 60000

EXERCISE
Exercise 5.52 Show the graph of load changes and working coefficients in the day Kng
and in the year Kn (Fig.5.29). Working time for design calculation 5 years. The drive is
designed according to the contact stress with T = Tmax and operates with a constant
number of revolutions n1 = 1200 rpm. Determine the equivalent number of cycles NE
in the scheme as shown in Figure 5.29
116 Chapter 5

Figure 5.29
Exercise 5.53 Given bd = 1, need to find ba when u = 1; 4 and 9.
Exercise 5.54 The straight spur gear with number of teeth z1 = 16, z2 = 84, ratio of
width face to center distance ba = 0,4. Calculate bm.
Exercise 5.56 The driving gear of the gear transmission with tooth number z1
(matching two gears z'2 and z2 in figure 5.30b) is made from coal-impregnated steel
with surface hardness of 58 HRC ( 580 HB). The load acting on the teeth changes
cyclically as shown in Figure 5.30a. Working time 4 years. Working coefficient for the
year Kn = 0.66, coefficient of working for the day Kng = 0.66. Rotational speed n1 =
500 rpm. Let's define:
a) The equivalent number of cycles to NHE1 driving gear.
b) Allowable contact stress [H1] of the driving gear.

Z2
T (Mômen xoắn)

T Z1

0,5 0,5
T T
0,01s t (thời gian)
0,01s 0,01s Z’2

Chu kỳ tck = 0,1s

Gear Drive 117

a) b)
Figure 5.30

Exercise 5.64 The spur gear transmission (bearing symmetry) transmits torque T =
200 Nm, the number of revolutions of the driving gear n 1 = 1248 rpm, gear ratio u =
2. The material is normalization 40Cr alloy steel with a hardness of 290 HB. Life
coefficient KHL= KFL=1. Let's define:
a) Allowable stress [H], [F].
b) Modulus m, number of teeth z1, z2 and center distance a in the case of a covered,
well-lubricated gear transmission.
b) Module m, number of teeth z 1, z2 and shaft distance a in case of open gear
transmission.
c) Compare the results calculated on sentences a) and b). Explain why we often use a
well-lubricated, covered transmission?
Exercise 5.70 Determine the torque that a well-lubricated spur gear drive can transmit,
given that: number of gear teeth z1 = 30, gear pitch diameter d1 = 80 mm, gear ratio u =
4 , bd = 0.6, number of revolutions of driving gear n1 = 600 vg/min, driven gear
material – C45 steel, [H] = 510 MPa.
Exercise 5.72 Calculation of spur gear transmission according to contact stress.
Transmission power P = 25 kW. The equivalent number of cycles of the driving gear
NHE = 4.5,107. The number of revolutions of the driving gear n1 = 905 rpm, the driven
gear n2 = 425 rpm. The gear pair is made of low-alloy steel, which is carburizing, heat
treatment to reach a hardness of 58 - 63 HRC.
Exercise 5.73 The spur gear transmission transmits the power P1 = 7 kW, the number
of revolutions n = 1240 rpm. Transmission ratio u = 2.13. Gear material - normalized
C45 steel. The load varies according to figure 5.33. Working time Lh = 8000 hours.
The gear is located symmetrically with the bearing.
a) Calculate the allowable contact stress.
b) Design calculation of gear drive.

Figure 5.33
Exercise 5.75. The single-stage gear reducer in the transmission system for the mixing
118 Chapter 5

tank (Fig. 5.34) has a power on the driving gear shaft P1 = 4.9 kW when the angular
velocity of driving gear 1 = 99.3 rad/s, driven gear 1 = 24.8 rad/s. Transmitter
working time Lh = 12000 hours. Static, non-reversing loads. The design calculation of
gear drive is required when:
a) Helical spur gear.
b) Bevel gear.

Figure 5.34