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DESIGN OF HELICAL GEARS-U.S. APPLICATION: Milling machine driven by an electric motor
Example Problem 10-3
Initial Input Data: Factors in Design Analysis:
Input Power: P= 20 hp Alignment Factor, Km =1.0+Cpf +Cma If F<1.0 If F>1.0 F/DP = 0.76
Input Speed: nP = 550 rpm Pinion Proportion Factor, Cpf = 0.051 0.082 [0.50 < F/DP < 2.00]
Transverse Diametral Pitch, P d : Pd = 3.464 Enter: C pf = 0.082 Figure 9-16
Number of Pinion Teeth: NP = 16 Type of gearing: Open Commer. Precision Ex. Prec.
Desired Output Speed: nG = 146.6 rpm Mesh Alignment Factor, Cma = 0.305 0.181 0.111 0.073
Computed number of gear teeth: 60.0 Enter: C ma = 0.181 Figure 9-17
Enter: Chosen No. of Gear Teeth: NG = 60 Alignment Factor: K m = 1.26 [Computed]
Computed data: Overload Factor: K o = 1.25 Table 9-7
Actual Output Speed: nG = 146.7 rpm Size Factor: K s = 1.05 Table 9-8: Use 1.00 if P d >= 5
Gear Ratio: m G = 3.75 Pinion Rim Thickness Factor: K BP = 1.00 Fig. 9-18: Use 1.00 if solid blank
Pitch Diameter - Pinion: DP = 4.619 in Gear Rim Thickness Factor: K BG = 1.00 Fig. 9-18: Use 1.00 if solid blank
Pitch Diameter - Gear: DG = 17.321 in Dynamic Factor: Kv = 1.16 [Computed: See Fig. 9-20] For Kv :
Center Distance: C= 10.970 in Service Factor: SF = 1.00 Use 1.00 if no unusual conditions B = 0.5202
Pitch Line Speed: vt = 665 ft/min C = 76.87
Transmitted Load: Wt = 992 lb Reliability Factor: K R = 1.00 Table 9-11 Use 1.00 for R = .99
Enter: Design Life: 10000 hours See Table 9-12
Secondary Input Data: Pinion - Number of load cycles: NP = 3.3E+08 Guidelines: YN , ZN
7
Transverse pressure angle: φ t = 28.30 deg Gear - Number of load cycles: NG = 8.8E+07 10 cycles >107 <107
Helix angle: ψ = 30.0 deg Bending Stress Cycle Factor: Y NP = 0.96 1.00 0.96 Fig. 9-22
Axial Pitch: p x = 1.5708 in Bending Stress Cycle Factor: Y NG = 0.98 1.00 0.98 Fig. 9-22
Min. Face Width (2 x Axial Pitch): F min = 3.142 in Pitting Stress Cycle Factor: Z NP = 0.92 1.00 0.92 Fig. 9-24
Enter: Face Width: F = 3.500 in Pitting Stress Cycle Factor: Z NG = 0.95 1.00 0.95 Fig. 9-24 Through Hardened
Enter: Elastic Coefficient: Cp = 2300 Table 9-10 Stress Analysis: Bending Grade 1 Steel
Enter: Quality Number: A v = 8 Table 9-3 Pinion: Required s at = 3,337 psi See Fig. 9-11 or HB -122 Fig. 9-11
REF: NP, NG = 16 60 Gear: Required s at = 3,339 psi Table 9-5 HB -122 Fig. 9-11
Enter: Bending Geometry Factors: Stress Analysis: Pitting
Pinion: J P = 0.593 Fig 10-5,6,7 Pinion: Required s ac = 56,220 psi See Fig. 9-12 or HB 84 Fig. 9-12
Gear: J G = 0.579 Fig 10-5,6,7 Gear: Required s ac = 54,537 psi Table 9-5 HB 79 Fig. 9-12
Enter: Pitting Geometry Factor: I = 0.233 Tab. 10-1,2 Specify materials, alloy and heat treatment, for most severe requirement.
REF: mG = 3.75
Axial Force: W x = 573 lb AISI 1020
Radial Force: Wr = 534 lb
DESIGN OF HELICAL GEARS-U.S. APPLICATION: Milling machine driven by an electric motor
Example Problem 10-3
Initial Input Data: Factors in Design Analysis:
Input Power: P= 20 hp Alignment Factor, Km =1.0+Cpf +Cma If F<1.0 If F>1.0 F/DP = 0.61
Input Speed: nP = 550 rpm Pinion Proportion Factor, Cpf = 0.036 0.067 [0.50 < F/DP < 2.00]
Transverse Diametral Pitch, P d : Pd = 3.464 Enter: C pf = 0.067 Figure 9-16
Number of Pinion Teeth: NP = 20 Type of gearing: Open Commer. Precision Ex. Prec.
Desired Output Speed: nG = 146.6 rpm Mesh Alignment Factor, Cma = 0.305 0.181 0.111 0.073
Computed number of gear teeth: 75.0 Enter: C ma = 0.181 Figure 9-17
Enter: Chosen No. of Gear Teeth: NG = 75 Alignment Factor: K m = 1.25 [Computed]
Computed data: Overload Factor: K o = 1.25 Table 9-7
Actual Output Speed: nG = 146.7 rpm Size Factor: K s = 1.05 Table 9-8: Use 1.00 if P d >= 5
Gear Ratio: m G = 3.75 Pinion Rim Thickness Factor: K BP = 1.00 Fig. 9-18: Use 1.00 if solid blank
Pitch Diameter - Pinion: DP = 5.774 in Gear Rim Thickness Factor: K BG = 1.00 Fig. 9-18: Use 1.00 if solid blank
Pitch Diameter - Gear: DG = 21.651 in Dynamic Factor: Kv = 1.18 [Computed: See Fig. 9-20] For Kv :
Center Distance: C= 13.712 in Service Factor: SF = 1.00 Use 1.00 if no unusual conditions B = 0.5202
Pitch Line Speed: vt = 831 ft/min C = 76.87
Transmitted Load: Wt = 794 lb Reliability Factor: K R = 1.00 Table 9-11 Use 1.00 for R = .99
Enter: Design Life: 10000 hours See Table 9-12
Secondary Input Data: Pinion - Number of load cycles: NP = 3.3E+08 Guidelines: YN , ZN
7
Transverse pressure angle: φ t = 28.30 deg Gear - Number of load cycles: NG = 8.8E+07 10 cycles >107 <107
Helix angle: ψ = 30.0 deg Bending Stress Cycle Factor: Y NP = 0.96 1.00 0.96 Fig. 9-22
Axial Pitch: p x = 1.5708 in Bending Stress Cycle Factor: Y NG = 0.98 1.00 0.98 Fig. 9-22
Min. Face Width (2 x Axial Pitch): F min = 3.142 in Pitting Stress Cycle Factor: Z NP = 0.92 1.00 0.92 Fig. 9-24
Enter: Face Width: F = 3.500 in Pitting Stress Cycle Factor: Z NG = 0.95 1.00 0.95 Fig. 9-24 Through Hardened
Enter: Elastic Coefficient: Cp = 2300 Table 9-10 Stress Analysis: Bending Grade 1 Steel
Enter: Quality Number: A v = 8 Table 9-3 Pinion: Required s at = 2,647 psi See Fig. 9-11 or HB -131 Fig. 9-11
REF: NP, NG = 20 75 Gear: Required s at = 2,629 psi Table 9-5 HB -132 Fig. 9-11
Enter: Bending Geometry Factors: Stress Analysis: Pitting
Pinion: J P = 0.600 Fig 10-5,6,7 Pinion: Required s ac = 44,561 psi See Fig. 9-12 or HB 48 Fig. 9-12
Gear: J G = 0.590 Fig 10-5,6,7 Gear: Required s ac = 43,226 psi Table 9-5 HB 44 Fig. 9-12
Enter: Pitting Geometry Factor: I = 0.238 Tab. 10-1,2 Specify materials, alloy and heat treatment, for most severe requirement.
REF: mG = 3.75
Axial Force: W x = 458 lb AISI 1020
Radial Force: Wr = 427 lb
Contact Ratio-Spur Gears
Input Data:
No. of teeth - Pinion = 16
No. of teeth - Gear = 64
Diametral pitch = 6
Pressure angle = 20 degrees
Computed Results:
Outside radius - Pinion = 1.500 in
Base radius - Pinion = 1.253 in
Outside radius - Gear = 5.500 in
Base radius - Gear = 5.012 in
Center distance = 6.667 in
Circular pitch = p = 0.524 in