MECH 323 Machine Design

2002 Fall Term

Solution To Problem Set # 2 - AGMA Calculation of Gear Stress

Q# 1
Known

<Pinion>
Np = 23
Pd = 6
= 25
Qv = 9

<Gear>
Ng = 57
Pd = 6
= 25
Qv = 9

Tp = 7878 in-lb
AISI 4140 Steel
r.p.m. = 1000

Tg = 19524 in-lb
Class 40 Cast Iron

Face width factor = 8

b =

Wt Pd K a K m

Ks K B K I
FJ
KV

Bending failure safety factor, N b =

Find

Part a)

and

S fb =

KL
S fb '
KT TR

S fb

a) Factor of safety of both pinion and gear;

b) A factor of safety of at least 2 by adjusting Pd & face width.
- First calculate the face width: F =

8
8
= = 1.333 in.
Pd 6

- Ka = 1 since torque is assumed to be steady.

- Km = 1.6 since the face width is less than 2 in.
- Find the velocity factor, Kv
Vt =

B=

dp

P =

23 / 6
N P / Pd
P =
1000rpm 2 = 1003 ft/min
2
2 (12 in / ft )

(12 QV ) 2 / 3 (12 9 )2 / 3
=
= 0.520 , and
4
4

A = 50 + 56 (1 B ) = 50 + 56 (1 0.520 ) = 76.880

A
Kv =
A+ V
t

0.520

76.88

=
= 0.836

76
.
88
+
1003

- Ks = 1 for both pinion and gear. KB = 1 since the gears are too small to have spokes.
- KI = 1 since both gears are not idling.
- From Table 11-13, take Jp = 0.42 and Jg = 0.49.
(more on next page)

MECH 323 Machine Design

2002 Fall Term

Wt =

- Calculate Wt:
bP =

bg =

2 Pd TP 2 6 7878
=
= 4110 lb
23
NP

(4110) (6) (1) (1.6)

(1) (1) (1) = 84,307 and

(1.333) (0.42) (0.836)
(4110) (6) (1) (1.6)

(1) (1) (1) = 72,263

(1.333) (0.49) (0.836)

- Find the Correct Strength of Pinion and gear:

Set KL = 1 and KT = 1 since no information on life cycle and temperature is provided.
KR= 1 by assuming a 99% reliability.
For AISI 4140 Steel, SfbP = 34,000 psi from Table 11-20.
(1)
34,000 = 34,000 psi
(1) (1)
For Class 40 Cast Iron, Sfbg = 13,000 psi from Table 11-20.

S fbP =

S fbG =

(1)
13,000 psi
(1) (1)

- Find the Bending Failure Safety Factor of Pinion and Gear:

Nbp =
Answer:

NbG =

S fbP

bP

34,000
= 0.403 (Bending failure safety factor of Pinion)
84,307

13,000
= 0.180 (Bending failure safety factor of Gear)
72,263

S fbG

bG

Note that both values of safety factor are much smaller than 2!
Part b)

Iterate to find the minimum safety factor of at least 2 by adjusting Pd.

Recall that Face Width Factor = F * Pd = 8. Therefore, we found:
Face Width
Factor
8
8
8
8

Pd
4
3
2.5
2

Face Width
[in]
2.00
2.67
3.20
4.00

bP
[psi]
24980
10538
6099
3122

NbP
1.361
3.226
5.575
10.889

bG
[psi]
21411
9032
5227
2676

NbG
0.607
1.439
2.487
4.857

Answer: By inspection, when Pd = 2.5 and face width = 3.2 in, Nbp = 5.575 and Nbp = 2.487
would be the minimum safety factor greater than 2.
Part c)
Q# 2

The estimated bending-failure safety factors using the Lewis Equation are much larger,
and that tells us the Lewis Equation is less accurate than the AGMA calculations.

MECH 323 Machine Design

2002 Fall Term

Known

<Pinion>
Np = 23
= 25
Qv = 9

Tp = 7878 in-lb
AISI 4140 Steel
r.p.m. = 1000

<Results from Q# 1>

Ka = 1
KT = 1
Ks = 1
KR = 1
KI = 1
Km = 1.7
KL = 1
KV = 0.836

<Gear>
Ng = 57
= 25
Qv = 9

Tg = 19524 in-lb
Class 40 Cast Iron

KB = 1
Vt = 2407 ft/min
A = 76,880
B = 0.520

Wt = 1713 lb
Pd = 2.5
F = 3.2 in.
NbP = 4.857 and NbG = 2.167

Face width factor = 8

c = CP

Wt
C C
a m CS C f
F I d
CV

and S fc =

S fc

Surface fatigue failure safety factor, N c =

CL CH
S fc '
CT C R

Find

A factor of safety of at least 2 by adjusting Pd and face width.

Solution

- C P = 2100 psi for Steel Pinion and Cast-Iron Gear in Table 11-18.
- Set Ca, Cm, Cv and Cs equal to Ka, Km, Kv, and Ks respectively.
Ca = 1 , Cm = 1.7, Cv = 0.836, and Cs = 1
- The gears are made by conventional methods, so set CF = 1.
- Find the radii of curvature of the pinion (p ):
2

1 + xP

rp cos 2
p = rp +
cos
Pd
Pd

N p / Pd

23 / 2.5
= 4.6 in.
2
2
2
xp = 0 since the teeth are standard.

where rp =
and

dp

2
1+ 0

o 2
p = 4.6 +
cos 25o = 1.621 in.
4.6 cos 25
2
.
5
2
.
5

- Find the radii of curvature of the gear (g):

MECH 323 Machine Design

2002 Fall Term

4
(Subtract p because the teeth are external)

g = C sin p
C = rp + rg = 4.6in +

dg
2

= 4.6in +

N g / Pd
2

= 4.6in +

57 / 2.5
in = 16 in
2

g = (16 ) sin 25o 1.621 = 5.141

- Find factor I =

cos
1
1

+
d
p g p

(Add

cos 25o
= 0.121
1
1
+

(2 4.6in )
1.621 5.141

, because the teeth are external)

- Calculate surface-fatigue stress of the pinion and gear:

cp = (2100)

1713
(1) (1.7)

(1) (1) = 65,669 psi

(3.2) (0.121) (9.2) (0.836)

cg = (2100 )

1713
(1) (1.7)

(1) (1) = 41,714 psi

(3.2) (0.121) (22.8) (0.836)

- Find the corrected surface-fatigue strengths for the pinion and gear:
S fc =

CL CH
S fc ' where
CT C R

Sfcp = 155,000 psi and Sfcg = 75, 000 psi from Table 11-21;
CT = CR = 1 since CT and CR set equal to KT and KR respectively;
CL = 1 since there is no information on expected life-span of the gear set; and
CH = 1 since HBp/HBg = 230/200 = 1.15
Therefore, S fcp =

(1) (1) 155,000 psi, and similarly

(1) (1)

S fcg = 75,000 psi

- Find the surface-fatigue safety factor of the pinion and gear:

Answer:

155,000
75,000
N cP =
= 5.57 , and N cg =
= 3.23 (Both higher than 2. Good!)
65,669
41,714
- End of Q# 2 Solution -