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115 viewsModule 4 Text Book - Helical Gear Design
Uploaded by
Abinandh VCopyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF or read online on Scribd
/ 16
CHAPTER 2
HELICAL GEARS
Helical gear has tect
for two helical gears on para
same helix angle and be of oppo
h in form of helix around the gear. In orde:
Hel shafis to be mesh, they must have the
site hands. The initial contact of helica
gear is a point, which becomes a line of snerensing Iengi fs contac
continues. Because of gradual engagement of the i h, ean gear rut
more quietly than spur gears and can be operate ane Pi cl i
Velocities, A disadvantage of helical gears is that the helix ang! : rs
jn a thrust load in addition to the usual tangential and separating loads.
Definitions
Figure 2.1
helix angle is the angle between an element of the helical tooth and the
axis of rotation of the gear. The usual range of values used for helix angle
is between 15° and 30° It is denoted by B
Normal circular pitch p, is the distance between corresponding points
of adjacent teeth as measured in a plane perpendicular to the helix.
Transverse circular pitch p(axial pitch) is the distance between
corresponding points of adjacent teeth as measured in
a plane perpendicular to the axis of rotation. The geometric
relationship between the normal pitch P,, and the transverse pitch P; is
Py=PrcosB (Pa=7"y & P=)
Therefore m,=m cosh — (m=m)
where m, is the normal module and m,is the transverse module.
In helical gear, the pressure angle may be measured either in a plane
perpendicular to the axis of gear (transverse plane A-A) or ina plane
normal to the tooth (plane B-B) as shown in fig. (a) Fig (b) shows the
26
Scanned with CamScannertooth profiles in normal and transverse plane. The relation between the
pressure angle oy in the normal plane and pressure angle a in the plane
of rotation is,
tan ay =tan ay x cosp
S ‘4
A A
‘SRY ade
B
Vv Section A-A Section B-B
Figure 2.2
Formative or Equivalent Number of Teeth for Helical Gears
Referring the fig 2.3. the plane B-B normal
to the gear teeth intersects the pitch
cylinder to form an ellipse. The gear tooth
profile generated in this plane, using the
radius of curvature of the ellipse, would be a
spur gear having the same properties as the
actual helical gear.' The number of teeth of
the equivalent spur gear in the normal plane
is known as formative number of teeth or
equivalent number of teeth or virtual
number of teeth.
Radius of curvature of an ellipse re = d/(2cos’B) (1)
Where d = Pitch circle diameter of the gear
{Helix angle
2ar, _,
Equivalent number of teeth 2, =~" =2rat™n
2m ay
z,
"cos fh
From equations (1) and (2),
eal
Scanned with CamScanner_2m, d _dm,
5 cos 8 Joos? B cos’ B
Zy =z/cos* B
HELICAL GEAR FORCES
Figure2.4
The normal load acting on a helical gear are having 3 components
s 2M,
Tangential load Boy =F,cosa,cosp
Radial or separating load F,=F, sina,=F,tana;
Axial thrust F,= FytanB
“t=pressure angle on diametric plane
Gn=pressure angle on normal plane
B= helix angle
Scanned with CamScannerProportions for Helical Gears (DB table 12.20)
Though the ‘i '
gh the proportions for helical gears are not standardised, yet
following
the ration aR Gmascommented by American Gear Manfacturer's
Pressure angle in the plane of rotation.
. = 15° 23' to 25°
Helix angle § = 20° to 45°
Addendum m to 0.7 m
clearance 3 m to 0.157m
Thickness of tooth = 1.5708 m
Strength of Helical Gears
1.In helical gears, the contact between mating teeth is gradual,
starting at one end and moving along the teeth so that at any instant
the line of contact runs diagonally across the teeth. Therefore in
order to find the strength of helical gears, a modified Lewis
equation is used. It is given by
F=0,C,bamy
where F, = Tangential tooth load,
og= Allowable static stress,
Cy = Velocity factor,
b= Face width,
m= Module, and
y = Tooth form factor or Lewis factor
corresponding to the formative or virtual or
equivalent number of teeth. |
2.The dynamic tooth load on the helical gears is given by
K,v(Cbcos* B+ F)cosB
| KamiCbcos Pees
K,v+ Choos’ f+ F,
e strength of the tooth is
F, =F,
3.The static tooth load or enduranc
F,=o0,bYm,
4.limiting wear tooth load for helical gears is given by.
d,bOk
cos’ B
Scanned with CamScannerDesign procedure
1.From table 12.7 obtain allowable static stresses o, for the given
material Db 0
2.Calculate the speed and number of teeth on gears by using
i=(ny/n2)=(9/21)=(da/di) .
(* if the number of tecth is not given assume it from D B table
12.19
ie; minimum number ofiteeth!avoid interference)
3. Find virtual number of teeth DB 12.52a
4.Find lewis factor for virtual number of teeth (ze) for pinion and gear
using D'B 12.17a,12.17b,12:17¢
5.Calculate the strength factor for pinion and gear(ou*y)
which one is lesser then design that element
(tif. both pinion and gear are of same material then pinion
weaker,design should be based on weaker element)
6.Calculate torque on weaker element
= 2mmM,
‘se pao
use 60 e
7.Caleulate pitch line velocity ~~’
ain
“60%1000
8.Find velocity factor Cy use DB
12.19a,12.19b.12.19¢,12.19d,12.19e
= » anassume Cy=0.45 (if d is not given)
a 1000PC,
9.Find F, oe DB 12.20a
“DB table 12.8
1
_(2M,C, cosB
ae jormal_ module ™ -(Mc eee) DB 12.60
find module m=m,cosB_ D B 12.45
and round’off using D B table 12.2
try to select preferred (1) or choice (2)
then,find actual m,
here k=(b/m,) DB'12.58a°" use k=15
11. Find dy=mz;
Scanned with CamScannerdy=mz)
and gear proportions from D B table 12.20
12. Find Fadynamic load DB 12.62
13.Find F, the dynamic strength DB 12.63
14Find Fw the limiting wear load DB 12.64
15 Check R>F, & > F,,
design is safe
16.{f any condition is violated then do the following
~inerease the face width
-increase surface hardness by heat treatment
-decrease the tooth error ‘ e”
17. Draw figure of helical gear(D B page 206)
(Note : If the diameter or center distance between gears or velocity is
given, use the same procedure by not assuming the minimum number of
teeth)
if both conditions are satisfied
EXAMPLE PROBLEM & UNIVERSITY QUESTIONS
QI).A pair of helical gears subjected to heavy shock loading is to
transmit 37.5KW at 1750 rpm of the pinion. The speed reduction ratio is
4.25 and the helix angle is 15°. The service is continuous and the teeth
are 20° FD in normal plane Select suitable material and design the gears
calculate the major dimensions and draw the arrangement
(U Q 2008)
Given data
Assumptions
z= 20
xz, =4,25%20=85
Both pinion and gear are C45
Z=
Pinion is weaker since both are made of same material.
p= 2anM,
60
3 2%3.142x1750xM,
37.5x10 =
Scanned with CamScannerMe 204.73Nm
me 2M,C,, cos B
" o,CkY2
Cya1.15 (table 12.21)
k=15 (assume)
C,=0.45(assume)
y=0.154-(0.912/z-) DB 12.17b
Y =zy=0.354
1
3
} DB 12.60
1
2x 204.73 x10* x1.15x cos15° \3
233.4 x 0.45% 15x 0.354x 20
m,= 3.44 mm
m,=meosB DB 12.45
my _
= 3.56
cos B
round off the module (Table 12.2)
m=4mm
actual m,= mcosB=4*cos15=3.86mm
dy-mz, = 4*20= 80 mm
dp=m Zz = 4*35= 340 mm
b=km, DB12.58a
= 15*3.86 = 57.9mm
The normal diameter pitch
z
= DB 12.44
Pe Tos 8
-— 0 __ 1 5 19.60
oC, kY¥z
Cy=1.15 (table 12.21)
k=14(given)
C\=0.45(assume)
¥0.175-(095!z) DB 12.170
=ay=
3
15x10 =
1
_{ 2*14.33x10° x1.15xcos30° )3
“(0 100% 0.45x14x0.46x24
m= 1.59mm
m,=mcosB DB 12.45
~cos30° ~ 183
round off the module (D BTable 12.2)
m=3 mm
actual m,= mcosB=2.59mm
Scanned with CamScannerdy=-m 21 = 4*24= 72 mm
d)-m 2) = 4*96= 288 mm
b=km, = 14*2,59 = 36.37 mm
1000PC,
Ff =——— D.B 12.30
1000 60 1000x6097 68m/s
Cs=1
= 1000x15x1
‘ 37.68
= 398.09 N
rina Kote Be es
DB 12.62
K,v+ Choos? B+ F, )
C=118.7 (error 0.01) Table 12.12
20.67 x 37.68(118.7 x 36.37 x cos” 30 +398.09)cos30
F, =398.09 +
20.67 x 37.68 + s|118.7x36.37x cos? 30 + 398.09
=3320.6N
d,bOK
Fy = 0 DB 12.64
cos
Q= 2 z = 2(96)=1.6[D.B 12.36C] K=1.108 (table 12.16)
ZytZ, 96424
_ 72x 36.37 x1.6x1.108 = 6189.7N
cos’ B
Fy2Fa Design safe for wear
i i it 30K W power at a speed
i of helical gears to transmit 3 erat a
oe see the input shaft rotates at 2000rpm. Take bax and
reduction Rure angles as 25° and 20° respectively both pinion and gear
are nade of steel having the following strength properties
Pinion og pinion=55 MPa BHN 340 wich
Gear cy gear-40 MPa BHIN 300
A)given data
P=30KW &
Scanned with CamScannerin 4
ny = 2000 rpm
n2 = 500 rpm
B =25°
a =20° stud
G4 pinion=55 Mpa
Sa gear=40 Mpa
ze, = —0_ = 26.8
cos’ B
similarly 2.2 = 107.46
Strength factor
y=0.154-(0.912/z.) D B12.17b
For pinion = 55*0.376=20.7
For gear=40*0.457=18.27
Therefore gear is weaker
Therefore we will design gear
p= 2an,M,
60
3
30x10 = ee
M,= 573.2Nm
_(2M,C, cosB
" o{C,k¥z
Cy1.15 (table 12.21)
k=15(assume)
C,=0.45(assume)
y=0.154-(0.912/ze) DB12.17b Y=ay=0.457
1
3
} DB 12.60
1
_( 2x573.2x10° x1.15xcos25° \)
"40x 0.45 x15x0.457x 20
m,= 7.85mm.
m,=meosB DB 12.45
m= = 78S 8.66
cos cos25°
round off the module (Table 12.2)
m= 9mm
Vac
Scanned with CamScannerActual m,= mcosB=8.15mm.
dj-m Zz = 9*20= 180 mm
d)=m 22 = 9*80= 720 mm
kmy
b= 15*8.15 = 122.35 mm
1000PC
= DB 1230
adn x 180% 2000
yo — dis = 2%180%2000 _ 1g gam
** y000%60 100060 *
1000x301
=e = 398,
eae 398.09 N
:
F, =F +| KaCooos’ b+ F088 pg 12.6
K,v+JCheos B+F,
C=114.4 (error 0.01) Table 12.12
20.67 x18,845(114.4 x 122.35 cos? 25 + 1592.3)cos 25
20.67 x 18.84 + ,/114.4 x 122.35 x cos’ 25 + 1592.3
F, =1592.3+
= 10776.5SN
F.=0,bYm, DB 12.63
40*122.35 *0.457 *8.15
= 18227.9N
p 480K
"cos? B
DB 12.64
Q= 2.2 = 2(80) =1.6[D.B 12.36C] K=1.599 (table 12.16)
z+z, 80420
20122-35216 1399 = 68595,16N .
cos’ 25
F,2Fa & Fw2Fu
Therefore Design is safe
Scanned with CamScannerQ4)A helical cast steel gear with 30” helix angle has to transmit 35KW
at 1500rpm if the gear has 24 teeth, determine module , pitch diameter
and face width for 20° FD.the static stress for cast steel may be taken as
56MPa the width of face may be taken as 3 times the normal pitch what
would be the end thrust on the gear?the tooth factor may be taken as
0.154-0.912/Te where Te represents the equivalent number of teeth
(U Q 2007)
A)given data
P=35 KW
ny = 1500 rpm
i= 4
B =30°
64 =S6Mpa
a =20° Fp
zy =24
b= 3P,
b= 3am,—D.B 12.43
b= 9.42 my
Since both pinion and gear are made of cast steel pinion is weaker
z= —4 =369
2x3.142x1500x M,
60
Me 22922Nm = 222-97
me 2M,C, cos B
gC k¥2
3
35x10 =
1
3
} DB 12.60
Cy=1.15 (table 12.21)
k=9.42(given)
C,=0.45(assume)
y=0.154-(0.912/ze) DB 12.17b ¥=y=0.405
1
_{ 2x 222.9210? x1.15xcos30° 3
"(0 56x0.45x9.42x0.405x 24
mp= 5.77mm.
Scanned with CamScannerAst My MST Jou
cos —Gos30* $98
round off the module (T;
rpund off th 2 (able 12.2)
actaual mn=m * cosB= 6.06mm
dy =m zy = 7x 24= 168 mm
b=km, D.R i230
b=9.42*6.06=57.08mm
1000PC, rx 180%2
oxoy DB 1230.40
v
adi | x168x1500: 90.05
pad FX168x15005 9
1000x80~ ~ to00x60 ~ 118m
1000 35X08) HK Joos
13.18) Be
=2655.5N . .
F.=FtanB ~" D.B12.51 0 ~~
Axial Thrust= F,= 2655,5*tan30?; =1533,17N, >
t
Q5). A pair of helical gears is to be désigned to transmit 20KW at a
pinion’ ‘speed of 1500rpm the velocity ratio is 2.5 selecting suitable
materials determine the dimensions of the gears (U Q 2008)
A) bYm, 1) B 12.63
Given, data ><
P=20KW ,
ny = 1500 rpm.
5 DBI
assumptions ’
B=15° :
@=202FD 2480) 1-0[!z= 2000%! a :
=
Z, =1% =4,25x 20 = 85, ,
th inion and gear are C45 ,
Pais is weaker since both are made of same material.
i & kw 2t
sre Igsign is sale
60
Scanned with CamScanner* _2x3.14«1500% M,
20x10
60,
Me 127.38Nm
\
m, , D B12.60
o CRY
Cy=h15 (table 12.21)
k=15(assume)
0.45(assume)
154-(0.912/2e) DB12.17b Y=my=0.354
2 127.38x 10° x1.15xcos15°
233.4 0.45 x15x 0.354% 20
{
m,= 2.93 mm
m,=mecosB D B 12.45
2.93
cos15
round off the module (Table 12.2)
m= 3.5mm
m =3.03mm
i
actual m, = mcosB=3.5*cos15=3.38
The normal diameter pitch
Zz
P.= DB 12.44
deosf
20
= __-0.295mm = 0.2
70cosis® mm = 0.295mm
; ; P,
Circular pitch p=—2— DB 12.43
al P cos #
= 09295 _ 9 306mm
cosl5
dn _1%10%1500 _. sosnyg
T000x60 100060
p= WOOF, DB 12.30
‘ v
Scanned with CamScannerF= 1000x 20x1
=——_—
5.495
= 3639.6N
Kyv+ Choos’ B+ F jee 12.62
i, ~songs{ Rasen esctetene regent)
20.67 x 7.32 + (114.4 x 50.7 x cos” 15 + 3639.6
C=114.4
= 8413.7N
F,=0,bYm, DB12.63
= 233.4-*50.7 *0.354 *3.38
= 14158.8N
a,b.
r=% D BIZ.
cos’ # $
Q= 2 _z = 2(85)=1.42[D.B 12.36C] K=0.539 (table 12.16)
zy+z, 85420
- 70x 50.7 x 1.42 « 0.539
cos? 15
=2911.3N
w
F,2Fa but Fw
