ME 452: Machine Design II

Solution to Homework Set 9

Problem 1 (Problem 14-15, page 781)

A steel spur pinion and gear have a diametral pitch of 12 teeth/inch, milled teeth, 17 and 30 teeth
respectively, a 20 degree pressure angle, and a pinion speed of 525 rpm. The tooth properties are Sut =
76 kpsi, Sy = 42 kpsi, and the Brinell hardness is 149. For a design factor of 2.25, a face width of
0.875 inches, what is the power rating of the gear set?

SOLUTION:

In general, you should use the AGMA approach for gear analysis, since it is more accurate. But
the AGMA approach, at least as summarized in our book, does not give any way to check yield
strengths of the gears. This is usually acceptable, because for gears the cycles are so high that fatigue
usually dominates. Other than its historical significance, the primary usefulness of the Lewis equation
is to check gear tooth yield. Note that ultimate and yield strengths are given in this problem statement,
not AGMA fatigue strengths, so the methods of Chapter 6 and the Lewis equation will be used in the
solution which follows. Problem 2 of this homework set will focus on the AGMA approach.
Since the pinion and the gear of the given spur gear set have the same material properties then the
power that the gear set can transmit is governed by the failure of the pinion. The problem is to
determine: (i) the power that can be transmitted considering pinion tooth bending failure, and, (ii) the
power that can be transmitted considering pinion tooth wear. The power rating of the gear set will
then be the minimum of these two power ratings (for the specified design factor of 2.25).
Consider bending of the pinion tooth.

The diameter of the pinion, see Equation (13-1), page 676, can be written as

NP
dP =
P

where P is the diametral pitch; i.e., number of teeth per inch. Therefore, the diameter of the pinion is

17
dP = = 1.417 in
12

The pitch line velocity, see Example (14-1), page 740, can be written as

π dP nP
VP = ft / min
12

Therefore, the pitch line velocity is given as

π × 1.417 × 525
VP = = 194.8 ft/min
12

1
The uncorrected endurance strength for Sut < 200 kpsi , see Equation (6-8), page 282, can be written as

Se′ = 0.5 Sut

Therefore, the uncorrected endurance strength is

Se′ = 0.5 × 76 = 38 kpsi

The surface factor, see Equation (6-19), page 287 can be written as

k a = a Sutb

For milled (machined) teeth, see Table (6-2), page 288, the factor a and the exponent b are given as

a = 2.7 and b = − 0.265

Therefore, the surface factor is

k a = 2.7 × (76) −0.265 = 0.857
Assuming full depth teeth, the sum of the addendum and dedendum, see Figure (14-1), page 737, and
Table (13-1), page 696, can be written as
1 1.25 1 1.25
l= + = + = 0.1875 in
P P 12 12

The tooth thickness, see Equation (b), page 737 and Figure (14-1), page 737, can be written as

t= 4l x

where the value of the distance x , see Equation (14-3), page 737, can be written as

3Y
x=
2P

The Lewis form factor for the pinion with 17 teeth, see Table (14-2), page 738, is

Y = 0.303

Therefore, the distance x for the pinion is

3 × 0.303
x= = 0.0379 in
2 × 12
Therefore, the tooth thickness for the pinion is

t = 4 × 0.1875 × 0.0379 = 0.1686 in

2
The effective diameter for bending, see Equation (6-25), page 289, can be written as

d e = 0.808 ( h b )
1/ 2

where h = F = Face width = 0.875 in and b = t = tooth thickness = 0.1686 in . Therefore, the effective
diameter is
d e = 0.808 × ( 0.875 × 0.1686 ) = 0.310 in
1/ 2

The size factor, see Equation (6-20), page 288, can be written as
−0.107 −0.107
 d   0.310 
kb =   =  = 0.996
 0.3   0.3 

The loading factor for bending, see Equation (6-26), page 290, is

kc = 1

The temperature factor, assuming operation at room temperature, see Table (6-4), page 291, is
kd = 1
The reliability factor, assuming 50 % reliability, see Table (6-5), page 293, is
ke = 1
The miscellaneous effects factor to account for one-way bending, see Example 14-2, page 742, is
k f = 1.66

The fully corrected endurance strength, see Equation (6-18), page 287, is

Se = ka kb kc kd ke k f Se′

Therefore, the fully corrected endurance strength is

Se = 0.857 × 0.996 ×1×1×1×1.66 × 38.0 = 53.84 kpsi

To estimate the stress concentration effects at the root of the tooth, see Figure (14-1), page 737 and
Example 14-2, page 740, is
0.3 0.3
rf = = = 0.025 in
P 12

The ratio r / d in Figure A-15-6, page 1027, is

r rf 0.025
= = = 0.148
d t 0.1686

3
The ratio D / d in Figure A-15-6, page 1027, is equal to infinity for a gear tooth. Since Figure A-15-6
does not have a curve for D / d = ∞ then approximate D / d = 3 . Therefore, the theoretical stress
concentration factor from Figure A-15-6 is
Kt ≈ 1.68

For the Neuber constant, note that we need to use Sut= 76 kpsi, in equation 6-35a, page 296:

a = .246 − .331(10 −2 )76 + .151(10−4 )762 − .267(10−7 )763 = 0.0874 in

and r = 0.025 = 0.1581 in

The fatigue stress concentration factor is then given by Equation (6-33), page 296, as

Kt − 1
K f = 1+
1+ a
r

Therefore
1.68 − 1
K f = 1+ = 1.438
1 + 0.0874 / 0.1581

The allowable bending stress for a design factor of 2.25, see Example 14-2, page 742, can be written
as
Se 53.84
σ all = = = 16.64 kpsi = 16, 640 lb/in 2
K f nd 1.438 × 2.25

The tangential component of the load, see Equation (14-7), page 739 and Example 14-2, page 740, can
be written as
F Y σ all
Wt =
Kv P

The dynamic (or velocity) factor for milled teeth, see Equation (14-4b), page 739, can be written as

1200 + VP
Kv =
1200

Therefore, the dynamic factor is

1200 + 194.8
Kv = = 1.162
1200

4
Therefore, the tangential component of the load is

0.875 × 0.303 × 16, 640

Wt = = 316.4 lb
1.162 × 12

The transmitted power (with bending of pinion teeth as the design criterion), see Example 14-2, page
740, can be written as
W t VP
H=
33,000

Therefore, the transmitted power (with bending of pinion teeth as the design criterion) is

316.4 ×194.8
H= = 1.87 hp
33, 000

Pinion Tooth Wear.

The surface stress (i.e., Hertzian contact stress), see Equation (14-14), page 744, can be written as
1/ 2
 K W t  1 1 
σ C ,all = −C p  v  + 
 F cos φ  r1 r2  

The elastic coefficient C p , for a steel pinion in mesh with a steel gear, see Table 14-8, page 757, is

C p = 2300 psi

The radii of curvature of the tooth profiles at the pitch point, see Equation (14-12), page 744, are

d P sin φ d G sin φ
r1 = and r2 =
2 2

Therefore the radii of curvature of the tooth profiles at the pitch point are
1.417 × sin 20°
r1 = = 0.242 in
2
2.5 × sin 20°
and r2 = = 0.428 in
2
The surface endurance strength, see Equation (6-68), page 329, can be written as

( SC )10 8 = 0.4 H B − 10 kpsi

Therefore, the surface endurance strength is

( SC )10 8 = 0.4 × 149 − 10 = 49.6 kpsi

The allowable contact stress, see Example 14-3, page 745, can be written as

5
 SC
σ C ,all =
nd

Therefore, the allowable contact stress is

49.6
σ C ,all = − = −33.067 kpsi
2.25
Note that the negative sign is because σ C is a compressive stress. The tangential component of the
load, see Equation (14-14), page 744, can be written as
2
 −σ   F cos φ 
W =  C ,all
t
  
 C
 p   K v (1/ r1 + 1/ r2 ) 

Therefore, the tangential component of the load is

 −33067  0.875 × cos 20°

2
 
Wt =    1.162 × (1/ 0.242 + 1/ 0.428)  = 22.6 lb
 2300   

The transmitted power, see Example 14-2, page 740, can be written as

W t VP
H=
33,000

Therefore, the transmitted power (with wear of pinion teeth as the design criterion) is

22.6 × 194.8
H= = 0.133 hp
33,000

Conclusion: The power rating considering pinion tooth wear is lower than the power rating
considering pinion tooth bending. Therefore, the power rating of the spur gear set is
H rated = 0.133 hp

Note the significant discrepancy between the ratings for contact stress and bending stress, almost a
factor of 10. Note also that the material has a very low hardness number. Significant improvement in
the gear set rating could be obtained by increasing the hardness of the tooth to 450 Brinell, for
example. Then the surface endurance strength is

( SC )108 = 0.4 × 450 − 10 = 170 kpsi

Therefore, the allowable contact stress is

170
σ C , all = − = −113.3 kpsi
2.25
Therefore, the tangential component of the load is

6
  −113,300   0.875 × cos 20°
2

Wt =    = 265.5 lb
 2300  1.162 × (1 / 0.242 + 1 / 0.428) 

Therefore, the transmitted power (with wear of pinion teeth as the design criterion) is

265.5 ×194.8
H= = 1.56 hp
33, 000

Then the rated power of the gear set is still governed by tooth contact stress, but the ratings for
bending and contact stress are similar. The power rating is 1.56 Hp, limited by contact stress.

Problem 2 (Problem 14-19, page 782)

A commercial enclosed gear drive consists of a 20 degree spur pinion having 16 teeth driving a 48
tooth gear. The pinion speed is 300 rpm, the face width is 2 inches, and the diametral pitch is 6
teeth/inch. The gears are grade 1 steel, through-hardened at 200 Brinell, made to #6 quality standards,
uncrowned, and are to be accurately and rigidly mounted. Assume a pinion life of 108 cycles and a
reliability of 90%. Determine the AGMA bending and contact stresses and the corresponding factors
of safety if 5 hp is to be transmitted.

SOLUTION:
The diameter of the pinion, see Equation (13-1), page 676, is

NP
dP =
P

Therefore, the diameter of the pinion is

16
dP = = 2.667 in
6
Similarly, the diameter of the gear, see Equation (13-1), page 676, is
NG
dG =
P
Therefore, the diameter of the gear is
48
dG = = 8 in
6
The pitch line velocity, see Example (14-1), page 740, can be written as

π dP nP
V=
12

Therefore, the pitch line velocity is

7
 π × 2.667 × 300
V= = 209.4 ft/min
12
The transmitted power, see Example 14-2, page 740, can be written as

W t VP
H=
33,000

Therefore, the tangential component of the load is given as

33, 000 H 33, 000 × 5
Wt = = = 787.9 lb
VP 209.4
The AGMA bending stress equation, see Equation (14-15), page 746, can be written as

Pd K m K B
σ = W t Ko K v K s
F J

The overload factor, assuming uniform loading, see page 758, is

Ko = 1

The dynamic factor, see Equation (14-27), page 756 can be written as
B
 A+ V 
Kv =  
 A 

where the exponent B , see Equation (14-28), page 756 is

B = 0.25 ( 12 − Qv ) 2 / 3

Therefore, for the specified transmission accuracy-level number, Qv of 6, the exponent B is

B = 0.25 × (12 − 6) 2 / 3 = 0.8255

The factor A , see Equation (14-28), page 756, can be written as

A = 50 + 56 ( 1 − B )

Therefore, the factor A is

A = 50 + 56(1 − 0.8255) = 59.77
Therefore, the dynamic factor is
0.8255
 59.77 + 209.4 
Kv =   = 1.196
 59.77 
The size factor, see Equation (a), page 759, can be written as

8
 0.0535
F Y
K S = 1.192 
 P 
 

The Lewis form factor for the pinion with 16 teeth, see Table (14-2), page 738, is

Y = 0.296

The Lewis form factor for the gear with 48 teeth, see Table (14-2), page 738, using linear interpolation
is

Y = 0.4056

Therefore, the size factor for the pinion is

0.0535 0.0535
F Y  2 0.296 
( KS )P = 1.192 
 P 
= 1.192 
  = 1.088
   6 

Similarly, the size factor for the gear is

0.0535 0.0535
 F YG   2 0.4056 
( K S )G = 1.192 
 P  = 1.192   = 1.097
   6 

The load distribution factor, see Equation (14-30), page 759, can be written as

K m = 1 + Cmc (C pf C pm + CmaCe )

The load correction factor Cmc for uncrowned teeth, see Equation (14-31), page 760, is

Cmc = 1

The pinion proportion factor C pf for a face width of F = 2 in , see Equation (14-32), page 760, is

F
C pf = − 0.0375 + 0.0125 F
10 d

Therefore, the pinion proportion factor C pf is

2
C pf = − 0.0375 + 0.0125 × 2 = 0.0625
10 × 2.667

Assuming S1 / S < 0.175 in Figure (14-10), page 760, then from Equation (14-33), page 760, the pinion
proportion modifier C pm is
C pm = 1

9
The mesh alignment factor Cma , see Equation (14-34), page 760, can be written as

Cma = A + BF + CF 2

For commercial enclosed unit, see Table (14-9), page 760, the factors A, B, and C are

A = 0.127 B = 0.0158 and C = −0.930 ×10−4

Therefore, the mesh alignment factor Cma is

Cma = 0.127 + (0.0158 × 2) − (0.930 ×10 −4 × 2 2 ) = 0.158

The mesh alignment correction factor Ce , see Equation (14-35), page 760, is

Ce = 1

Therefore, the load distribution factor is

K m = 1 + 1× [(0.0625 ×1) + (0.158 ×1)] = 1.221

Assuming the backup ratio mB ≥ 1.2 , the rim thickness factor, see Equation (14-40), page 764 is

KB = 1

The geometry factor for bending strength for the pinion with 16 teeth from Figure (14-6), page 753,
assuming that the load is applied at the highest point of single-tooth contact (HPSTC) is

J P = 0.27

The geometry factor for bending strength for the gear with 48 teeth from Figure (14-6), page 753,
assuming that the load is applied at the highest point of single-tooth contact is

J G ≈ 0.38
The AGMA bending stress for the pinion can then be written as

Pd K m K B
(σ ) P = W t K o K v ( K s ) P
F JP

Therefore, the AGMA bending stress for the pinion is

6 1.221×1
(σ ) P = 787.9 ×1×1.196 ×1.088 × × = 13,910 psi
2 0.27

The AGMA bending stress for the gear can be written as

10
 Pd K m K B
(σ ) G = W t K o K v ( K s ) G
F JG

Therefore, the AGMA bending stress for the gear is

6 1.221×1
(σ )G = 787.9 ×1×1.196 ×1.097 × × = 9964 psi
2 0.38
The safety factor guarding against bending fatigue failure, see Equation (14-41), page 765, can be
written as
StYN / KT K R
SF =
σ

From Figure (14-2), page 747, the AGMA bending strength for the pinion and the gear made of Grade
1 steel can be written as
( St ) P = ( St )G = 77.3H B + 12,800 psi
Therefore, the AGMA bending strength for the pinion and the gear are

( St ) P = ( St )G = 77.3 × 200 + 12,800 = 28, 260 psi

The pinion life is specified to be 108 cycles. The gear ratio of the given gearset is

N G 48
mG = = =3
N P 16

Therefore the life of the gear in cycles is 108 / 3 cycles.

The stress cycle factor for bending strength for the pinion, see Figure (14-14), page 763, with N = 108
cycles and considering the upper curve in the shaded region is
(YN ) P = 1.3558 N −0.0178 = 1.3558 × (108 ) −0.0178 = 0.977
The stress cycle factor for bending strength for the gear, see Figure (14-14), page 763, with
N = 108 / 3 cycles and considering the upper curve in the shaded region is
(YN )G = 1.3558 N −0.0178 = 1.3558 × (108 / 3) −0.0178 = 0.996
The reliability factor, see Table (14-10) page 764, for a reliability of 0.9 is

K R = 0.85

The temperature factor, assuming oil and gear-blank temperatures less than 250° F , see page 764, is

KT = 1

11
Then the safety factor guarding against bending fatigue failure for the pinion can be written as

( St ) P (YN ) P / KT K R
( SF )P =
(σ ) P
Therefore, the safety factor guarding against bending fatigue failure for the pinion is
(28, 260 × 0.977) /(1 × 0.85)
( SF ) P = = 2.33
13,921
The safety factor guarding against bending fatigue failure for the gear can be written as

( St )G (YN )G / KT K R
( S F )G =
(σ ) G
Therefore, the safety factor guarding against bending fatigue failure for the gear is

(28, 260 × 0.996) /(1 × 0.85)

( S F )G = = 3.32
9973

The AGMA pitting resistance (contact stress) equation, see Equation (14-16), page 746, is

Km C f
σ c = C p W t Ko K v K s
dPF I

The elastic coefficient C p , for a steel pinion in mesh with a steel gear, see Table (14-8), page 757, is

C p = 2300 psi

The surface condition factor, C f , see page 758 is assumed to be equal to 1.

The geometry factor for pitting resistance, see Equation (14-23), page 735, for an external gearset can
be written as
cos φt sin φt mG
I=
2m N mG + 1

For spur gears, see page 755, the load-sharing ratio mN = 1 and φt = φ . Therefore, for the given spur-
gear set the geometry factor for pitting resistance is

cos 20° sin 20° 3

I= = 0.1205
2 ×1 3+1

Then, the AGMA contact stress for the pinion is

12
 Km C f
(σ c ) P = C p W t Ko K v ( K s ) P
dPF I

Therefore, the AGMA contact stress for the pinion is

1.221 1
(σ c ) P = 2300 × 787.9 ×1×1.196 ×1.088 × × = 101,503 psi
2.667 × 2 0.1205

The AGMA contact stress for the gear is

Km C f
(σ c ) G = C p W t K o K v ( K s )G
dPF I

Therefore, the AGMA contact stress for the gear is

1.221 1
(σ c )G = 2300 × 787.9 ×1×1.196 ×1.097 × × = 101,922 psi
2.667 × 2 0.1205

The safety factor guarding against pitting failure, see Equation (14-42), page 765, can be written as

Sc Z N C H / KT K R
SH =
σc

From Figure (14-5), page 750, the AGMA surface endurance strength for the pinion and the gear made
of Grade 1 steel can be written as
( Sc ) P = ( Sc )G = 322 H B + 29,100 psi
Therefore, the AGMA surface endurance strength for the pinion and the gear are

( Sc ) P = ( Sc )G = 322 × 200 + 29,100 = 93,500 psi

The stress cycle factor for pitting resistance for the pinion, see Figure (14-15), page 763, with N = 108
cycles and considering the upper curve in the shaded region is
( Z N ) P = 1.4488 N −0.023 = 1.4488 × (108 ) −0.023 = 0.948
The stress cycle factor for pitting resistance for the gear, see Figure (14-15), page 763, with
N = 108 / 3 cycles and considering the upper curve in the shaded region is

( Z N )G = 1.4488 N −0.023 = 1.4488 × (108 / 3) −0.023 = 0.973

13
Then the safety factor guarding against pitting failure for the pinion is

( Sc ) P ( Z N ) P C H / KT K R
( SH )P =
(σ c ) P

Therefore, the safety factor guarding against pitting failure for the pinion is

(93,500 × 0.948 ×1) /(1× 0.85)

( SH )P = = 1.03
101,503

The safety factor guarding against pitting failure for the gear is

( S c )G ( Z N )G C H / K T K R
( S H )G =
(σ c )G

Therefore, the safety factor guarding against pitting failure for the gear is

(93,500 × 0.973 ×1) /(1× 0.85)

( S H )G = = 1.05
101,922

14