M452 GEAR SPREADSHEET ANALYSIS-CONTENT 3 PDH course

Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

Boston Gear Revised 3-22-2020
http://www.bostongear.com/litportal/pdfs/P-1482BG_pg133-153.pdf

GEAR RATIOS DISCLAIMER: The materials conta

representation or warranty on th
named herein. The materials are
for competent professional advic
should be reviewed by a registere
Anyone making use of the inform
assumes any and all resulting liab

A spreadsheet cell con

be optimized by using
-
Some advantages of sp
written include:
 
1. easier to read.
2. better recall from
3. greater accuracy.
4. faster with repea
5. graphs are create
6. numerous useful
Case A Insert 7. "Goal Seek" enab
Gear-1 rotation speed, N1 = 800 rpm 8. solve equations w
Gear-1 number of teeth, T1 = 20 - 9. solve sets of line
Gear-2 number of teeth, T2 = 40 - 10. calculations and
Calculate documents and sl
Speed ratio: Gear-1 / Gear-2, R12 = T1 / T2
= 0.5 -
Gear-2 rotation speed, N2 = N1 * R12
= 400 rpm
Cases B & C Insert
Gear-1 rotation speed, N1 = 400 rpm
Gear-1 number of teeth, T1 = 40 -
Gear-2 number of teeth, T2 = 20 -
Gear-3 number of teeth, T3 = 60 -
Gear-4 number of teeth, T4 = 30 -
Calculate
Speed ratio: Gear-1 / Gear-2, R12 = T1 / T2
=2 -
Gear-2 rotation speed, N2 = N1 / R1
= 200 rpm
Speed ratio: Gear-3 / Gear-4, R34 = T3 / T4
= 2.000 -
Speed ratio: Gear-1 / Gear-4, R14 = R12*R34
= (T1/T2)*(T3/T4)
=4 -
Gear-4 rotation speed, N4 = N1 / R14
= 1600 rpm

SHAFT FORCES

Design of Power Transmission Shafting

The objective is to calculate the shaft size having the strength and rigidity required to transmit
an applied torque. The strength in torsion, of shafts made of ductile materials are usually
calculated on the basis of the maximum shear theory.

ASME Code states that for shaft made of a specified ASTM steel:
Ss(allowable) = 30% of Sy but not over 18% of Sult for shafts without keyways. These values
are to be reduced by 25% if the shafts have keyways.

Shaft design includes the determination of shaft diameter having the strength and rigidity to
transmit motor or engine power under various operating conditions. Shafts are usually round
and may be solid or hollow.

Shaft torsional shear stress: Ss = T*R / J

Polar moment of area: J = π*D^4 / 32 for solid shafts

J = π*(D^4 - d^4) / 32 for hollow shafts

Shaft bending stress: Sb = M*R / I

Moment of area: I = π*D^4 / 64 for solid shafts

Shaft torsional shear stress: Ss = T*R / J

Polar moment of area: J = π*D^4 / 32 for solid shafts

J = π*(D^4 - d^4) / 32 for hollow shafts

Shaft bending stress: Sb = M*R / I

Moment of area: I = π*D^4 / 64 for solid shafts

I = π*(D^4 - d^4) / 64 for hollow shafts

The ASME Code equation for shafts subjected to: torsion, bending, axial load, shock, and
fatigue is:
Shaft diameter cubed,
D^3 = (16/π*Ss(1-K^4))*[ ( (KbMb + (α*F α*D*(1+K^2)/8 ]^2 + (Kt*T)^2 ]^0.5

Shaft diameter cubed with no axial load,

D^3 = (16/π*Ss)*[ (KmMb)^2 + (Kt*T)^2 ]^0.5

K = D/d D = Shaft outside diameter, d = inside diameter

Km = combined shock & fatigue bending factor

Kt = combined shock & fatigue torsion factor

α = column factor = 1 / (1 - 0.0044*(L/k)^2 for L/k < 115

L = Shaft length
-
k = (I / A)^0.5 = Shaft radius of gyration

A = Shaft section area

For rotating shafts:

Kb = 1.5, Kt = 1.0 for gradually applied load

Kb = 2.0, Kt = 1.5 for suddenly applied load & minor shock

Kb = 3.0, Kt = 3.0 for suddenly applied load & heavy shock

Shaft having Bending and Torque
End
Inputload is small
shaft data enough
for yourtoproblem
ignore. below and Excel will calculate the answers, Excel's
"Goal Seek" may be used to optimize the design of shafts, see the Math Tools tab below.
Input
Motor Power, HP = 10.0 hp
Shaft speed, N = 1750 rpm
Shock & fatigue moment factor, Km = 2
Torque shock & fatigue factor, Kt = 3
Shaft allowable torsional shear stress: Ss = 18,000 psi
Shaft length, L = 8 in
Shaft moment, Mb = 3500 in-lbf
Calculation
Shaft Design Torque, T = 12*Kt*5252*HP / N
= 720 in-lbf
Shaft diameter, D = ((16/π*Ss)*[ (KtMb)^2 + (Km*T)^2 ]^0.5)^(1/3)
= 1.442 in

Shaft Polar Moment of Area and Shear Stress

 Solid Shaft
Input
Torsion, T = 360 in-lbf
Round solid shaft diameter, D = 2.000 in
Calculation
Section polar moment of inertia, J = π*D^4 / 32
= 1.571 in^4
Torsion stress, Ft = T*(D/2) / J
= 229 lb/in^2

Hollow Shaft Input

Torsion, T = 1,000 in-lbf
Hollow shaft outside dia, Do = 2.000 in
Hollow shaft inside dia, Di = 1.500 in
Calculation
Section polar moment of inertia, J = π*(Do^4 - Di^4) / 32
J = 1.074 in^4
Torsion stress, Ft = T*(Do/2) / J
= 931 lb/in^2

Drive Shaft Torque Twist Angle

Input
Shaft Design Torque from above, Q = 207 in-lbf
Shaft outside diameter, D = 1.500 in
Shaft inside diameter, d = 0.500 in
Torque applied to shaft length (see below), x = 8.00 in
Shaft material tension modulus, E = 29,000,000 psi
Shaft material shear modulus, G = 11,500,000 psi
Calculation
Section polar moment of area, J = π*(D^4 - d^4) / 32
= 0.491 in^4
Shear stress due to Td, ST = Q*D / (2*J)
= 316 lbf/in^2 < GOAL SEEK
Shaft torsion deflection angle, a = Q*L / (J*G)
= 0.000293 radians
= 0.017 degrees

Power Shaft Overhung Load W

 http://www.darali.com/disco/page9.pdf

Input
Motor power, HP = 2.0 hp
Shaft speed, N = 1,180 rpm
Pinion number of teeth, t = 20 -
Gear number of teeth, T = 60 -
Bevel pinion diametral pitch, DP = 8 Whole Number
Gear and pinion pressure angle, PA = 20.0 deg
Gearbox allowable overhung load, Wa = 500 lb
Overhung load location, x = 4.000 in
Gearbox efficiency, e = 90.0% -
Driver shaft diameter, d1 = 1.500 in
Driven shaft diameter, d2 = 2.500 in
Torque shock & fatigue factor, Kt = 3 -
Shaft outside diameter, D = 1.500 in
Shaft inside diameter, d = 1.000 in
Shaft length, L = 5.000 in
 Shaft allowable tension stress, St = 26,000 psi
Shaft allowable shear stress, Ss = 10,000 psi
Calculation
Driver gear pitch circle diameter, D1 = t / DP
2.500 in
Driven gear pitch circle diameter, D2 = T / DP
7.500 in
Driver Shaft Torque, Q1 = e*12*Kt*5252*HP / N
= 288 in-lb
Driven Shaft Torque, Q2 = Q1*D2 / D1
= 865 in-lb
Bevel gear tangential force, Ft = Q1 / (PCDp/2)
= 231 lb
Bevel gear separating force, Fr = Ft *TAN(PA/57.3)
4.027
Driver applied overhung load, W = S = Q1*D1 / 2
= 361 lb
Driver Shaft maximum Moment, M = W*x
= 1442 in-lb
Shaft section modulus, I = π*(D^4 - d1^4) / 64
= 0.1994 in^4
Moment tension stress at A, sm = M*(D/2) / I
= 5,424 psi
Shaft polar modulus, J = π*(D^4 - d1^4) / 32
= 0.3868
Torsion shear stress at A, st = Q1*(D/2) / J
= 559 psi
Resultant moment & torsion stress at A, sr = (sm^2 + st^2)^(1/2)
= 5,452 psi
Resultant moment & torsion stress at B, = Resultant moment & torsion stress at A
Safety Factors
Driver tension safety factor, SFt = St / sr
= 4.8
Driver shear safety factor, SFs = Ss / ss
= 17.9
Driver overhung load safety factor, SFo = Wa/W
= 1.39

Gear Forces
Bevel Pinion or Gear Data Input
Whole Numbers
Motor power, HP = 7.5 hp
Shaft speed, N = 1,750 rpm
Torque shock & fatigue factor, Kt = 2.0
Bevel pinion number of teeth, t = 20
Bevel gear number of teeth, T = 40
Bevel pinion diametral pitch, PD = 6 Whole Number
Gear and pinion pressure angle, PA = 20.0 deg
Calculation
Bevel pinion pitch circle diameter, PCDp = t / DP
= 3.333 in
Bevel gear pitch circle diameter, PCDg = T / DP
= 6.667 in
Driver Shaft Torque, Q1 = Kt *5252*HP / N
= 45.0 ft-lb
= 540 in-lb
Driven Shaft Torque, Q2 = T1 *PCDg / PCDp
= 1080
Pinion pitch cone angle, B = 57.3 *ATAN(t / T)
= 26.57 deg
Bevel gear tangential force, Ft = Q1 / (PCDp/2)
= 324 lb
Bevel gear separating force, Fr = Ft *TAN(PA/57.3)
= 118.0 lb
Fp = Fr *SIN(B/57.3)
= 52.8 lb
Fg = Fr *COS(B/57.3)
= 105.5 lb

Note: The units of angle in Excel are radians.

degrees = radians*57.3

END OF WORKSHEET
 IMER: The materials contained in the online course are not intended as a
entation or warranty on the part of PDH Center or any other person/organization
herein. The materials are for general information only. They are not a substitute
mpetent professional advice. Application of this information to a specific project
be reviewed by a registered architect and/or professional engineer/surveyor.
e making use of the information set forth herein does so at their own risk and
es any and all resulting liability arising therefrom.

A spreadsheet cell containing a formula numerical value can

be optimized by using the “Goal Seek” tool in Excel.
-
Some advantages of spreadsheet calculations over hand
written include:
 
1. easier to read.
2. better recall from archives.
3. greater accuracy.
4. faster with repeat use.
5. graphs are created automatically.
6. numerous useful formulas.
7. "Goal Seek" enables optimization.
8. solve equations with, "Solver".
9. solve sets of linear and non-linear equations.
10. calculations and graphs may be pasted into
documents and slide show presentations.
Manual Transmission Video
http://www.youtube.com/watch?v=ftdgB93QOD8&feature=related
GEARBOX EFICIENCY
Most gearmotor manufacturers (Dodge, SEW-Eurodrive, Nord,
Falk, etc) will list "generalized" efficiencies for a particular type of
gearing configuration.
For example, helical gears = 0.96, worm gears = .85.
Most manufacturers will specify an intended gearbox operating
point.
Gearbox efficiencies in a spur gearbox at a 16-mm (5/8-in) diameter
vary from about 87% at a gear ratio of 6.3:1 to about 40% at a ratio of
10,683:1.
A basic rule that designers use for spur gears is a 10% loss per
engagement.
One gear wheel in contact with another is defined as an engagement
and the loss in that engagement is approximately 10%.
A general rule is the lighter the load and the higher the ratio, the less
likely it is that the gearbox will actually reach the manufacturers'
specified efficiency. Light loading and
high ratios tend to produce poor gearbox efficiencies.
Gearbox efficiencies in a spur gearbox at a 16-mm (5/8-in) diameter
vary from about 87% at a gear ratio of 6.3:1 to about 40% at a ratio of
10,683:1.
A basic rule that designers use for spur gears is a 10% loss per
engagement.
One gear wheel in contact with another is defined as an engagement
and the loss in that engagement is approximately 10%.
A general rule is the lighter the load and the higher the ratio, the less
likely it is that the gearbox will actually reach the manufacturers'
specified efficiency. Light loading and
high ratios tend to produce poor gearbox efficiencies.
But with heavy loading and high
ratios, the gearbox will approach its theoretical efficiency.
Overall system efficiencies depend on the efficiency of the motor and
gearbox together. If the
efficiency of the motor and gearbox is each 50%, the two efficiencies
are multiplied together to yield the system efficiency (0.5 x 0.5 or 0.25,
or a system efficiency of 25%).
At low ratios, motors are more heavily loaded than the gearboxes. A
low reduction ratio lets the motor "see" more of the load than at a
high ratio. For
example, the maximum efficiency of a 22:1 gearbox is about 76% and
the maximum efficiency of the motor is about 80%. However, the two
don't occur at the same time. When the motor reaches its peak
efficiency, gearbox efficiency is closer to 63% instead of 74%.
Therefore, when the motor is
at peak efficiency the gearbox is not — in low ratios.
This is a critical issue.
Assuming the gearbox has a constant efficiency leads to incorrect
calculations. In this case, a 10% efficiency difference could mean a lot
in the overall system efficiency. At
higher gearbox ratios, motor and gearbox efficiencies follow similar
curves because at that point the gearbox sees more of the load than
does the motor. This
leads to peak efficiencies in both gearbox and motor.
Variable motor speeds present another set of variables in the overall
equation. However, at
about 150:1 to 200:1, the gearbox and motor efficiencies peak at the
same time. To use the least
amount of power, it's critical to match the motor, gearbox, and load
closely to get the best system efficiencies.
http://www.micromo.com/Data/Sites/1/technical-library-pdf/ff-
1_gearboxefficiencies_md.pdf
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

http://shopswarf.orconhosting.net.nz/spur.html

GEAR FORCES

1. The objective is to calculate the shaft size having the strength

and rigidity required to transmit an applied torque.

2. The design bending is equal to the applied moment multiplied

by a combined stress concentration and fatigue factor Kf.

2. The strength in torsion, of shafts made of ductile materials

are usually calculated on the basis of the maximum shear theory.

3. The design torsion is equal to the applied to torsion multiplied

by a combined stress concentration and fatigue factor Ks.

Shaft Diameter for Combined Torsion and Bending

Fatigue Safety Factor Design

SPUR GEAR FORCES Input Data

Motor or drive bearbox power, P = 10 hp
Shaft speed, N = 1750 rpm
Moment factor, Cm = 1.5
Torque factor, Ct = 2.0
 Spur driver gear pitch circle diameter, D = 10.000 in
Gear pressure angle, A = 20 deg
Calculations
Motor torque, T = Kb*Kt*12*5252*HP / N
= 1080 in-lbs
Gear pitch circle radius, R = D / 2
= 5.000 in
Tangential force, Ft = T / R in-lbs
Ft = 216 lbs
Radial force, Fr = Ft * Tan A in-lbs
Fr = 79 lbs

GEAR SHAFT LOADS

The above tangential, Ft and radial, Fr forces

cause fully reversed bending in the shaft
as it rotates.

Driver gear applies forces Ft and Fr

to the driven gear. Equal and opposite
Ft and Fr forces are applied to the driver
gear. (Newton's first law)
Shaft Moment and Torque
Use this side to solve problems Input Data
Length from left bearing to gear, A = 3.00 in
Length from right bearing to gear, B = 5.00 in
Calculations
Vertical shaft bending moment
Sum of moments about any point in the shaft = 0
Sum of moments about the right bearing = R1*(A+B) - Fr*B
R1v = Fr*B / (A+B)
R1v = 49 lbs
Mv = R1*A
Mv = 147 in-lbs
Horizontal driven shaft bending moment
Sum of moments about any point in the shaft = 0
Sum of moments about the right bearing = R1*(A+B) - Fr*B
R1h = Ft*B / (A+B)
R1h = 135 lbs
Mh = R1*A
Mh = 405 in-lbs
Maximum fully reversed fatigue bending moment in the shaft (Mmax):
Mmax = (Mv^2 + Mh^2)^0.5
Mmax = 431 in-lbs

Calculate Shaft Diameter

Input Data
Motor torque (from above), T = 1080 in-lb
Shaft maximum moment (from above) Mmax = M = 431 in-lb
Allowable shaft shear stress, Sa = 5800 psi
ASME Code Load Case = C -
ASME Code Load Factor (from above), Cm = 1.5 -
ASME Code Load Factor (from above), Ct = 2.0 -
Given safety factor, SF = 2.00 -
Shaft outside diameter, D = 1.238 in
Shaft inside diameter, d = 0.000 in
Calculations
Ratio of inner to outer diameters of the shaft, k = d / D = 0.00
Allowable shaft shear stress, Sa = (16 / ((π*D^3)*(1-k^4))) * (((Cm*M + ((a*F*D(1 +k^
Subtract Sa, 0 = (16 / ((π*D^3)*(1-k^4))) * (((Cm*M + ((a*F*D(1 +k^
Use Goal Seek D value to make equation = 0 = 0 psi
 Input Data
Goal Seek Shaft diameter from above, Dg = 1.238 in
Next larger standard shaft diameter, D = 1.250 in

When using Excel's Goal Seek, unprotect the spread sheet by selecting:
Drop down menu: Tools > Protection > Unprotect Sheet > OK
When Excel's Goal Seek is not needed, restore protection with:
Drop down menu: Tools > Protection > Protect Sheet > OK
 40.0 Mpa

See "Goal Seek" tab below.

-k^4))) * (((Cm*M + ((a*F*D(1 +k^2)/8))^2 + (Ct*T)^2)^(1/2)

-k^4))) * (((Cm*M + ((a*F*D(1 +k^2)/8))^2 + (Ct*T)^2)^(1/2) - Sa
ASME Code Load Factors (K) Moment Torque
Stationary shaft: Load Case Cm Ct
Load gradually applied A 1.0 1.0
Load suddenly applied B 1.5 to 2.0 1.5 to 2.0
Rotating shaft: Moment Torque
Load gradually applied Load Case 1.5 1.0
Load suddenly applied (minor shock) C 1.5 to 2.0 1.5 to 2.0
Load suddenly applied (heavy shock) D 2.0 to 3.0 1.5 to 3.0

ASME Code for Commercial Steel Shafting

Shafts without keyway, Sa = 8000 psi 55 Mpa
Shafts with keyway, Sa = 5800 psi 40 Mpa
ASME Code for Steel Purchased Under Definite Specifications
Sa = 30% of the yield strength but not over 18% of the ultimate
strength in tension for shafts without keyways.
These values are to be reduced by 25% for the presence of keyw

Input Data
Shaft material yield stress, Sy = 36000 psi 248 Mpa
Shaft material ultimate stress, Su = 62000 psi 427 Mpa

Shaft Without Keyway Calculations

30% of material yield strength = 10800 psi
18% of material ultimate strength = 11160 psi
Shaft With Keyway
25% of 30% of material yield strength = 8100 psi
25% of 18% of material ultimate strength = 8370 psi

EXAMPLE ONLY
SPUR GEAR FORCES Input Data
Motor power, P = 10 hp
Shaft speed, N = 1750 rpm
Moment factor, Cm = 1.5
Torque factor, Ct = 2.0
Spur gear pitch circle diameter, D = 10.000 in
Gear pressure angle, A = 20 deg
Calculations
Motor torque, T = Kb*Kt*12*5252*HP / N
= 1080 in-lbs
Gear pitch circle radius, R = D / 2
 = 5.000 in
Tangential force, Ft = T / R in-lbs
Ft = 216 lbs
Radial force, Fr = Ft * Tan A in-lbs
Fr = 79 lbs

Shaft Moment and Torque

Use this side is an example Input Data
Length from left bearing to gear, A = 3.00 in
Length from right bearing to gear, B = 5.00 in
Calculations
Vertical shaft bending moment
Sum of moments about any point in the shaft = 0
Sum of moments about the right bearing = R1*(A+B) - Fr*B
R1v = Fr*B / (A+B)
R1v = 49 lbs
Mv = R1*A
Mv = 147 in-lbs
Horizontal shaft bending moment
Sum of moments about any point in the shaft = 0
Sum of moments about the right bearing = R1*(A+B) - Fr*B
R1h = Ft*B / (A+B)
R1h = 135 lbs
Mh = R1*A
Mh = 405 in-lbs
Maximum fully reversed fatigue bending moment in the shaft (Mmax):
Mmax = (Mv^2 + Mh^2)^0.5
Mmax = 431 in-lbs
EXAMPLE ONLY
Calculate Shaft Diameter
Input Data
Motor torque (from above), T = 1080 in-lb
Shaft maximum moment (from above) Mmax = M = 431 in-lb
Allowable shaft shear stress, Sa = 5800 psi 40.0 Mpa
ASME Code Load Case = C -
ASME Code Load Factor (from above), Cm = 1.5 -
ASME Code Load Factor (from above), Ct = 2.0 -
Given safety factor, SF = 2.00 -
Shaft outside diameter, D = 1.238 in
Shaft inside diameter, d = 0.000 in
Calculations
k = d / D = 0.00
Allowable shaft shear stress, Sa = (16 / ((π*D^3)*(1-k^4))) * (((Cm*M + ((a*F*D(1 +k^2)/8))^2 + (C
Subtract Sa, 0 = (16 / ((π*D^3)*(1-k^4))) * (((Cm*M + ((a*F*D(1 +k^2)/8))^2 + (C
Use Goal Seek D value to make equation = 0 = 0 psi
 Input Data
Goal Seek Shaft diameter from above, Dg = 1.238 in
Next larger standard shaft diameter, D = 1.250 in
er 18% of the ultimate

25% for the presence of keyways.

+ ((a*F*D(1 +k^2)/8))^2 + (Ct*T)^2)^(1/2)
+ ((a*F*D(1 +k^2)/8))^2 + (Ct*T)^2)^(1/2) - Sa
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

http://shopswarf.orconhosting.net.nz/spur.html

STRESS CONCENTRATION FACTORS

1. Static direct, bending, and torsion stresses are calculated first.

2. Static stress concentration factors are applied to the above static stresses.

3. Fatigue stress concentration factors modify the static stress concentration.

Static Stress in Round Shafts Input Data

Tension Force (+), Compression (-), F = 100 lbs
Moment, concave (+), convex (-), M = 300 in-lbs
Torsion, T = 600 lb-in
Shaft Diameter, D = 1.000 in
Calculations
Section Area, A = π*D^2 / 4 in^2
Section Area, A = 0.7855 in^2
Second Moment of Area, I = π*D^4 / 32 in^4
I = 0.0982
Polar Moment of Area, J = π*D^4 / 64 in^4
J = 0.0491 in^4
Direct stress (+) tension, (-) comp, σd = F / A
σd = 127 psi
Bending stress, σm = M*D / (2*I)
σm = 1528 psi
Torsional stress, τxy = T*D / (2*J)
τxy = 6111 psi
Given, σy = 0
Given x and y stresses above find static safety factor (N):
Input Data
Material tension yield stress, Syt = 36000 psi
Calculations
From above, σx = σd + σm = 1655 psi
From above, σy = 0 psi
From above, τxy = 6111 psi
von Mises' effective stress, σ’ = [ ( σx^2 + σy^2 – σx*σy + 3*τxy^2 ]^0.5
σ’ = 10713 psi
Material yield safety factor, N = Syt / σ’
N = 3.36

Geometric stress concentration D/d A b

factor (Kt) in static bending. 6.00 0.87868 -0.33243
 3.00 0.89334 -0.30860
2.00 0.90879 -0.28598
1.50 0.93836 -0.25759
1.20 0.97098 -0.21796
1.10 0.95120 -0.23757
1.07 0.97527 -0.20958
1.05 0.98137 -0.19653
1.03 0.98061 -0.18381
1.02 0.96048 -0.17711
1.01 0.91938 -0.17032

Static stress concentration factor (Kt) for the round shaft above in bending:
Input Data
Larger diameter, D = 4.000 in
Smaller diameter, d = 3.331 in
Notch radius, r = 0.250 in
Calculation
D/d = 1.20
Input Data From Table
Enter value from table above, A = 0.97098
Enter value from table above, b = -0.21796
Calculation
Kt = A *(r / d)^b
Answer: Kt = 1.71
Kt is the stress concentration factor (Kt) in static bending.
Input Data
Calculated nominal direct stress, σ = 24000 psi
Static notch concentration factor, Kt = 1.98
Calculation
Calculated max direct stress, σ = Kt*σ
σ = 47520 psi

Static stress concentration factor of a rectangular bar in bending.

 D/d=6 D/d=1.2
r/d Kt Kt
Kt Table 0.30 1.41 1.35
Geometric stress 0.25 1.48 1.40
concentration factor (Kt) in
static bending. 0.20 1.58 1.46
0.15 1.73 1.52
0.10 2.50 1.50
0.05 2.68 2.07

Kt is the stress concentration factor (Kt) in static bending.

Input Data
Notch radius, r = 0.125
Plate small depth, d = 1.250 -
Plate large depth, D = 1.500 -
Calculation
r/d = 0.10 -
D/d = 1.2
Input Data
Calculated nominal direct stress, σ = 30720 psi
Static concentration factor from table, Kt = 1.50
Calculation
Calculated max static direct stress, σ = Kt*σ
σ = 46080 psi

Notches and Stress Concentration in Fatigue Cyclic Loading

Geometric stress concentration factor ( Kf ) in fatigue bending.

Fatigue notch sensitivity factor, q = (Kf - 1)/ (Kt - 1)
or Fatigue notch sensitivity factor, q = 1 / (1 + a^0.5/ r^0.5)
a^0.5 = Neuber Constant
r = Notch Radius

Fatigue stress concentration factor (Kf) Sut (kpsi) (a)^0.5

50 0.130
 55 0.118
The fatigue stress concentration factor (Kf) is a 60 0.108
function of the sensitivity factor (q). 70 0.093
80 0.080
Input Data 90 0.070
Given ultimate tensile stress, kpsi, Sut = 80 100 0.062
Type input from table, (a)^0.5 = 0.080 110 0.055
Notch Radius, inches, r = 0.125 120 0.049
Copy Kt data fom table above, Kt = 1.500 130 0.044
Calculations 140 0.039
Fatigue notch sensitivity factor, q = 1 / (1 + a^0.5/ 160 0.031
q = 0.815 180 0.024
200 0.018
Fatigue concentration factor, (Kf) = 1 + q * (Kt - 1) 220 0.013
Answer: (Kf) = 1.408 240 0.009

Fatigue Notch Sensitivity Factor, q applied to the nominal stress:

Input Data
Tension (+ )compression (-) load, P = 1000 lbs
Section area, (se below) A = 4.125 in^2
Applied moment, M = 6000 in-lbs
Section second area of moment, (see below) I = 2.600 in^4
Distance, neutral axis to surface, c = 1.375 in
Calculations
nominal stress, σnom = P/A + M*c/ I
nominal stress, σnom = 3416 psi

Design fatigue endurance stress, σe = Kf * σnom

From calculation above, Kf = 1.408 -
σe = 4808 psi

Rectangular Sections: Input Data

Base, inches, B = 0.500
Height, inches, H = 1.250
H
Calculations
Section Area, A = B*H
A = 0.625 in^2
Section vertical second area of moment, I = B*H^3 / 12
B
I = 0.081 in^4

Circular Sections: Input Data

Diameter, inches, D = 1.500 in
 Calculations
Section Area, A = π*D^2 / 4 D
A = 1.767 in^2
Section vertical second area of moment, I = π*D^4 / 64
I = 0.2485 in^4
Section polar second area of moment, J = π*D^4 / 32
J = 0.4970 in^4

When using Excel's Goal Seek, unprotect the spread sheet by selecting:
Drop down menu: Tools > Protection > Unprotect Sheet > OK
When Excel's Goal Seek is not needed, restore protection with:
Drop down menu: Tools > Protection > Protect Sheet > OK
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

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SPUR GEARS

Circular pitch (CP) is the pitch circle arc length

between a point on one tooth and the corresponding
point on the adjacent tooth.
Diametral pitch (P) is the number of teeth per inch
of pitch circle diameter.

20°Pressure Angle (PA) is generally recognized as having higher load

carrying capacity than 14.5⁰ PA gears .

The 14.5⁰ pressure angle (PA) results in less backlash due to center

distance variation and concentricity errors than

20 degrees.

RUSH GEARS – download cad drawings from:

http://www.rushgears.com

Spur Gear Dimensions

Input
Pressure angle, Pa = 14.5 or 20 20 deg.
Diametral pitch (Whole Number), DP = N/D 5.0 -
Number of gear teeth (Whole Number), N = - 60 -
Gear hub diameter, h = - in
Gear hub width, w = - in
Bore diameter, b = - in
Calculation
Pitch circle diameter, D = N / DP 12.000 in
Addendum, A = 1 / DP 0.200 in
Dedendum, B = 1.157 / DP 0.231 in
Whole depth= Addendum+Dedendum, WD = 2.157 / DP 0.431 in
Clearance, C = .157 / DP 0.031 in
Outside diameter, OD = D + (2*A) 12.400 in
Root circle diameter, RD = D - (2*B) 11.537 in
Base circle diameter, BC = D*Cos(Pa/57.3) 11.276 in
Circular pitch of gear teeth, CP = π*D / N 0.628 in
Circular thickness of gear teeth, T = CP / 2 0.314 in
Chordal gear tooth thickness, TC = D*Sin(90/57.3)/N 0.200 in
Chordal addendum, AC = A + (T^2 / (4*D)) 0.202
 Working depth, WD = 2*A 0.400 in
Fillet radius at tooth base, Rb = 0.35 / DP 0.070 in
Note: Excel requires degrees to be converted to radians. Degrees x .01745 = Radians

Use the above spread sheet to calculate the dimensions of gears.

Gear Tooth Interference

There will be no interference if, Rbc < Ra Input
From above: Gear pitch circle diameter, PCg = 12.000 in
From above: Pinion pitch circle diameter, PCp = 4.000 in
From above: Gear = Pinion Addendum, A = 0.200 in
From above: Pressure angle, φ = 20 deg.
Calculation
Gear pitch circle radius, AG = PCg / 2
= 6.000 in
GX = AG*SIN(φ/57.30)
= 2.0520
Pinion pitch circle radius, BE = PCp/2
= 2.000 in
EX = BE*SIN(φ/57.30)
= 0.6840 in
GE = GX + EX
= 2.7360 in
Gear addendum radius, AE = (AG^2 + GE^2)^0.5
= 6.594 in
Gear addendum radius, AE = AG + A
= 6.200 in <<No interference

Pinion / Gear Speed Ratio and Center Distance

 Input
Pinion speed, Sp = 500 rpm
Desired Gear speed, Sg = 200 rpm
Pinion pitch circle diameter, Dp = 5.000
Diametral pitch of pinion & gear, P = 6 (Whole Number)
Calculation
Pinion teeth, Np = DP*P
= 30 -
Gear speed ratio, R = Sg / Sp
= 2.500
Gear teeth, Ng = R*Np
= 75.0
Gear pitch circle diameter, Dg = Ng / DP
= 12.500
Actual Gear speed, Sag = Sp / R
= 200.0 rpm
Pinion and Gear center distance, C = (Dp+Dg)/2
= 8.750

Spur Gear Teeth Stress

Spur Gear Tooth Bending Stress

 Input
Spur Gear Tooth load, W = 200 lbf
Tooth base thickness, t = 0.250 in
Tooth face width (into paper), b = 1.000 in
Pressure angle, Pa = 20 deg
Diametral pitch, Pd = 4 -
Number of gear teeth, N = 23.0 -
Calculation
Pitch circle diameter, D = N / Pd
= 5.758
Base circle diameter, BC = D*Cos(Pa/57.3)
= 5.411 in dia
Moment arm length, h = (D - BC)/2
= 0.174 in
Base half thickness, c = t / 2
c = 0.125 in
Section modulus, I = b*t^3 / 12
I = 0.001302083333333 in^3
Moment applied to tooth, M = W*h
= 35 in-lb
Gear tooth bending stress, Sb = M*c / I
Sb = 3,333 lbf/in^2
The stress calculated above does not include stress concentration or dynamic loading.

Gear Tooth Dynamic Load Input

Pitch line velocity, Vp = 100 ft/min
Tooth face width, b = 3.13 in
Gear torque, T = 1836 in-lbf
Circular pitch radius, R = CP / 2 = 3.00 in
Deformation factor (steel gears), C = 2950 - 4980
Calculation
Static load, F = 2*T / R
F = 1,224 lbf
Dynamic load, Pd = ((0.05*V*(b*C + F)) / (0.05*V + (b*C + F)^.5)) + F
Pd = 1,711 lbf
Strength of Gear Teeth
Strength of Gear Teeth- Lewis Equation - if pitch circle diameter is known
Input
Allowable gear tooth tensile stress, Sa = 20,000 lbf/in^2
Number of gear teeth, N = 100
Pressure angle, Pa = 20 deg
Tooth width, b = 1.000 in
Diametral pitch, DP = 4 Whole number
Lewis form factor, Y = 0.446 -
Calculation
Allowable gear tooth load, W = Sa*b*Y / DP
= 2230 lbf

Strength of Gear Teeth

Modified Lewis Equation
Input
Motor or drive gearbox power, HP = 7.50 hp
Motor = pinion speed, Sp = 1750 rpm
Diametral pitch, DP = 6.00 in
Pressure angle, Pa = 20 deg
Number of pinion teeth, n = 25
Number of gear teeth, N = 100
Pinion Lewis form factor, Yp = 0.341
Gear Lewis form factor, Yg = 0.446
Tooth face width (into paper), b = 1.000 in
Boston Gear material allowable stress, Sa = 25,000 psi
Calculation
Pinion torque, Q = 12*5252*HP / N
= 270 in-lbs
Pinion pitch circle diameter, Dp = n / DP Ref:
4.167 in
Gear pitch circle diameter, Dg = N / DP
= 16.667 in
Gear speed, Sg = Sp*n / N
= 437.5 rpm
Gear = Pinion pitch line velocity, V = Sp*Dp*π / 12
= 1909 ft/min
Velocity factor, vf = 600 / (600 + V)
= 0.2391
Pinion tooth load at pitch circle, Wp = Q / (Dp/2)
= 130 lbf
Gear tooth load at pitch circle, Wp = Q / (Dg/2)
= 32 lbf
Modified Lewis Formula Gear Tooth Stress
Pinion tooth Lewis stress, SLP = (DP*Wp /( b*Yp)) / vf
= 9,539 psi
Gear tooth Lewis stress, SLG = (DP*Wg /( b*Yg)) / vf
= 1,823 psi
Gear stress safety factor, SF = Sa / SLP
= 2.62
Gear Tooth Stress Moment Stress
Gear base circle diameter, BC = D*Cos(Pa/57.3)
= 15.662 in dia
Gear = Pinion tooth addendum, A = 1 / DP
= 0.167 in
Gear tooth moment arm length, A + h = A + (D - BC) / 2
= 0.669 in
Gear tooth chordal base thickness, t = π*Dg / (2*N)
= 0.262 in Ref:
Section modulus, I = b*t^3 / 12
I = 0.001495 in^3
Moment applied to tooth, M = W*h
= 87 in-lb
Gear = Pinion tooth bending stress, Sg = M*(t/2) / I
= 7,595 psi

The stress calculated above does not include stress concentration or dynamic loading.

This is the end of this spread sheet.

 Pinion / Gear Pressure Angle
GEAR ANIMATION http://en.wikipedia.org/wiki/Involute_gear

EXAMPLE ONLY
Stub Spur Gear Dimensions
Input
Pressure angle, Pa = 14.5 or 20 20 deg.
Diametral pitch (Whole Number), DP = N/D 4.0 -
Number of gear teeth (Whole Number), N = - 40 -
Gear hub diameter, h = - in
Gear hub width, w = - in
Bore diameter, b = - in
Calculation
Pitch circle diameter, D = N / DP 10.000 in
Addendum, A = 1 / DP 0.250 in
Dedendum, B = 1.157 / DP 0.289 in
Whole depth= Addendum+Dedendum, WD = 2.157 / DP 0.539 in
Clearance, C = .157 / DP 0.039 in
Outside diameter, OD = D + (2*A) 10.500 in
Root circle diameter, RD = D - (2*B) 9.422 in
Base circle diameter, BC = D*Cos(Pa/57.3) 9.397 in
Circular pitch of gear teeth, CP = π*D / N 0.785 in
Circular thickness of gear teeth, T = CP / 2 0.393 in
Chordal gear tooth thickness, TC = D*Sin(90/57.3)/N 0.250 in
Chordal addendum, AC = A + (T^2 / (4*D)) 0.254
 Working depth, WD = 2*A 0.500 in
Fillet radius at tooth base, Rb = 0.35 / DP 0.088 in

Do not use the example calculation above.

UNDERCUTTING When the

number of teeth in a gear is
small, the tip of the mating gear
tooth may interfere with the
lower portion of the tooth
profile.
To prevent this, the generating
process removes material at
this point.

This
results in loss of a portion of
the involute adjacent to the
tooth base, reducing tooth
contact and tooth strength.

On 14-1/2°PA
gears undercutting occurs
where a number of teeth is less
than 32 and for 20°PA less than
18.

Since this
condition becomes more severe
as tooth numbers decrease, it is
recommended that the
minimum number of teeth be
16 for 14-1/2°PA and 13 for
20°PA.
18.

Since this
condition becomes more severe
as tooth numbers decrease, it is
recommended that the
minimum number of teeth be
16 for 14-1/2°PA and 13 for
20°PA.

PINION AND GEAR CENTER DISTANCE

CENTER DISTANCE
Stock spur gears are cut to operate at standard center
distances.
The standard center distance being defined by:
Standard Center Distance = (Pinion PD + Gear PD) / 2
-
BACKLASH

When mounted at this center distance, stock spur gears will

have the following average backlash:
 BOSTON GEAR Lewis Equation Form Factor Y
Spur Gear Pressure Pressure
Teeth Angle 14 Angle 20
10 0.176 0.201
12 0.210 0.245
14 0.236 0.276
16 0.255 0.295
18 0.270 0.308
20 0.283 0.320
25 0.305 0.341
30 0.318 0.358
35 0.327 0.374
40 0.336 0.389
50 0.346 0.408
55 0.352 0.415
60 0.355 0.421
65 0.358 0.425
70 0.360 0.429
75 0.361 0.433
80 0.363 0.436
90 0.366 0.442
100 0.368 0.446
150 0.375 0.458
200 0.378 0.463
300 0.382 0.471
Rack 0.390 0.484
http://www.bostongear.com/litportal/pdfs/P-1482BG_pg133-153.pdf
http://www.prgmea.com/docs/tooth/70.pdf
Lewis gear tooth bending stress is based on the x dimension.
Gear tooth bending stress, SL = (DP*W) /( b*Yp)
An involute is a curve that is traced by a point on a cord
unwinding from a circle, which is called a BASE CIRCLE.
 GEARBOX EXAMPLE

Spur Gear Tooth load, W = 1,000 lbf

Tooth base thickness, t = 1.500 in
Tooth face width (into paper), b = 1.000 in
Pressure angle, Pa = 20 degrees
Diametral pitch, Pd = 4
Number of gear teeth, N = 32
 
a. 4,860 lbf/in^2
b. 5,860 lbf/in^2
c. 6,860 lbf/in^2
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012
Gleason Zerol Spiral Gears
http://www.qtcgears.com/Q410/PDF/techsec9.pdf

WORM GEARS

Worm Circular Pitch, Pc

AGMA Standard Circular Pitches (Fraction): 1/8, 5/16, 3/8, 1/2, 5/8, 3/4, 1, 1.25, 1.75, and 2.
AGMA Standard Circular Pitches (decimal): .125, .3125, .375, .500, .625, .750, 1.000, 1.250, 1.750, and 2.000

Worm & Wheel (or Gear) Dimensions (inches)

Input
 Worm and gear ratio, R = 20 -
Gear diametral pitch (Whole Number), DP = 6.00 -
Worm number of threads or starts, n = 2
Worm pitch, p = Gear pitch, P = 0.375 in
Worm pitch diameter, dw = 3.500 in
Worm and gear addendum factor, f = 0.318 -
Worm and gear whole depth factor, gd = 0.686 -
Gear OD factor, go = 0.4775 -
Gear hub diameter = in
Gear hub width = in
Bore diameter = in
Formula Calculation
Lead of worm, L = P*n 0.75 in
Number of gear teeth (Whole Number), N = n*R 40 -
Gear pitch circle diameter, DG = N / DP 6.667 in
Center distance between worm and gear, C = (dw + DG) / 2 5.083 in
Worm pitch circle diameter, Dw = 2C - DG 3.500 in
Worm Addendum, A = f *P 0.119 in
Worm or Gear whole depth, WD = gd * P 0.257 in
Worm or gear pitch, P = L/n 0.375 in
Worm outside diameter, ODW = dw + 2*A 3.739 in
Gear throat diameter, TD = DG + 2*A 6.905 in
Gear outside diameter, ODG = TD + go *P 7.084 in
Gear face width (1 or 2 threads), F = 2.38*P + .25 1.143 in < < n < 3, OK
Gear face width (3 or 4 threads), F = 2.15*P + .20 1.006 in < < n < 3, Not OK
Worm face length, FL = 6 *P 2.25
Worm lead angle, LA = 57.3*ATAN(L / (dw *3.1416))
3.902 degrees
Worm throat radius, TR = (0.5*dw) - A 1.631 in
Worm rim radius, RR = (0.5*dw) + P 2.125 in

Note: Excel requires degrees to be converted to radians. Degrees x .01745 = Radians

π = 3.1416
Use the above spread sheet to calculate the dimensions of worm and gear.

Strength of Worm & Wheel Gears - Lewis Equation

Input
Pitch circle diameter, Dp = 5.33 in
Rotational speed, n = 600 rpm
Ultimate stress, Su = 20,000 lbf/in^2
 Calculation
Gear Pitch Line Velocity, Vg = π*Dp*n / 12
Vg = 837 ft/min
Worm / Wheel allowable stress, So = Su / 3
So = 6,667 lbf/in^2
Worm/gear design stress, Sd = So*1200 / (1200 + Vg)
Sd = 3,927 lbf/in^2

Input
Worm/gear design stress from above, Sd = 3,927 lbf/in^2
Tooth width, b = 1.5 in
Circular pitch, Pnc = 1.0473 in
Lewis form factor, Y = 0.094 -
Calculation
Allowable gear tooth load, F = Sd*b*Pnc*Y -
F = 580 lbf

Worm Gear Dynamic Load Input

Static load, F = 1,723 lbf
Gear Pitch Line Velocity, Vg = 800 ft/min
Calculation
Worm Gear Dynamic Load, Fd = F*(1200+Vg) / (1200)
Fd = 2,872 lbf

Worm Gear Endurance Load Input

Worm/gear design stress, Sd = 4,000 lbf/in^2
Tooth width, b = 1.5 in
Lewis form factor, Y = 0.094
Worm wheel pitch circle diameter, Dp = 5.3 in
Calculation
Worm Gear Endurance Load, Fe = Sd*b*Y*π / Pnd
Fe = 334 lbf

Material Wear Constant

Worm Gear B
Hardened steel Cast iron 50
250 BHN steel Phosphor bronze 60
Hardened steel Phosphor bronze 80
 Hardened steel Antimony bronze 120
Cast iron Phosphor bronze 150

Worm Gear Wear Load Input

Gear pitch diameter, Dg = 5.3 in
Tooth width, b = 1.5 in
Material wear constant, B = 60 -
Calculation
Worm Gear Wear Load, Fw = Dg*b*
Fw = 477 lbf

Worm Gear Efficiency

Worm Circular Pitch, Pc

AGMA Standard Circular Pitches (Fraction): 1/8, 5/16, 3/8, 1/2, 5/8, 3/4, 1, 1.25, 1.75, and 2.
AGMA Standard Circular Pitches (decimal): .125, .3125, .375, .500, .625, .750, 1.000, 1.250, 1.750, and 2.000

Input Data
Motor power connected to worm gear, HP = 5 hp
Worm rotational speed, Nw = 1750 rpm Friction coefficients (f
Worm number of threads or starts, n = 2 http://www.roymech.
Worm pitch, p = Gear pitch, P = 0.375 degrees
Worm pitch diameter, dw = 3.500 in m/s
Number of gear teeth (Whole Number), N = 32 - 0
Gear diametral pitch (Whole Number), Pd = 6 0.001
Calculation 0.01
Lead of worm, L = p *n 0.05
= 0.750 0.1
Worm lead angle, LA = 57.3*ATAN(L / (dw *3.1416)) 0.2
= 3.902 deg 0.5
Note: for pressure angle = 20 deg A should be less than 25o 1
Worm rotational velocity at pitch radius, Vw = Nw*p*π 1.5
= 2062 in/min 2
Sliding velocity (m/s), VS = Vw / COS(LA/57.3) 5
= 2066 in/min 8
= 34.44 in/sec 10
= 2.87 ft/sec 15
= 0.875 m/s 20
Friction coefficient (f) for worm gears (Bronze -steel) 30
Coefficient of friction, f = 0,04 VS^-0,25
= 0.0414
 Calculation
Worm torque, Tw = 5252*HP / Nw
= 15.01 ft-lb
Worm gear torque friction force, Fwt = 12*Tw / (dw/2)
= 103 lb
Worm and gear ratio, R = N / n
= 16 -
Gear rotational speed, Ng = Nw / R
= 109.4 rpm
Gear torque, Tg = 5252*HP / Ng
= 240.1 ft-lb
Gear pitch circle diameter, DG = N / Pd
= 5.333 in
Worm gear thrust friction force, Fgt = 12*Tg / (DG/2)
= 1080 lb

Worm Gear Efficiency Range

http://www.qtcgears.com/Q420%20PDF%20Files/Section%209.pdf
Single thread, e = 40% to 50%
Double thread, e = 50% to 60%
Note: A worm gear must have less than 50% to be self locking.

AGMA Worm Gear Heat Dissipation Limit

Input
Worm to wheel center distance, C = 5.939 in
Transmission ratio, R = 16 -
Calculation
Maximum horse power limit, HPm = 9.5*C^1.7 / (R + 5)
HPm = 9.35 hp
This is the end of this spread sheet.
.250, 1.750, and 2.000
 Worm and Gear Addendum and Gear Factors
Worm Threads Addendum factor f Whole Depth gd Gear OD factor go
1 0.318 0.686 0.4775
2 0.318 0.686 0.4775
3 0.286 0.623 0.3183
4 0.286 0.623 0.3183

n < 3, OK
n < 3, Not OK
.250, 1.750, and 2.000

Friction coefficients (f) - For Case Hardened Steel Worm / Phos Bronze Wheel
http://www.roymech.co.uk/Useful_Tables/Drive/Worm_Gears.html

ft/s f
0 0.145
0.0032808 0.12
0.032808 0.11
0.16404 0.09
0.32808 0.08
0.65616 0.07
1.6404 0.055
3.2808 0.044
4.9212 0.038
6.5616 0.033
16.404 0.023
26.2464 0.02
32.808 0.018
49.212 0.017
65.616 0.016
98.424 0.016
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

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BEVEL GEARS

BEVEL or MITER GEAR PAIR

Bevel Pinion or Gear Data Input-1
Whole Numbers
Bevel pinion number of teeth, t = 20 -
Common diametral pitch, DP = 6 -
Bevel gear number of teeth, T = 48 -
Calculation-1
Bevel pinion pitch circle diameter, pcd = t / DP
= 3.333 in
Bevel gear pitch circle diameter, PCD = T / DP
= 8.000 in
Pinion pitch cone angle, pca = 57.3*ATAN(t / T)
 = 22.622 degrees
Gear pitch cone angle, PCA = 57.3*ATAN(T / t)
= 67.385 degrees
pca + PCA = 90.007 degrees
Pinion pitch cone radius, pcr = pd / (2*SIN(pca/57.3)
= 4.333 in
Gear pitch cone radius, PCR = PD / (2*SIN(PCA/57.3)
= 4.333 in

Same Bevel Pinion or Gear Data as above Input-2

Pressure angle, PA = 14.5 or 20 20 deg.
Diametral pitch (Whole Number), P = N/D 6 -
Number of gear teeth (Whole Number), N = - 47 -
Gear hub diameter = - in
Gear hub width = - in
Bore diameter = - in
Calculation-2
Pitch circle diameter, D = N / Pd 7.833 in
Addendum, A = 1 / Pd 0.167 in
Dedendum, B = 1.157 / Pd 0.193 in
Whole depth= Addendum+Dedendum, d = 2.157 / Pd 0.360 in
Clearance, C = .157 / Pd 0.026 in
Outside diameter, OD = D + (2*A) 8.167 in
Root circle diameter, RD = D - (2*B) 7.448 in
Base circle, BC = D*Cos(Pa/57.3) 7.361 in
Circular pitch of gear teeth, CP = π*D / N 0.524 in
Circular thickness of gear teeth, T = CP / 2 0.262 in
Chordal thickness, TC = D*Sin(90/57.3)/N 0.167 in
Working depth, WD = 2*A 0.333 in
Addendum angle, AA = 57.3*ATAN(A / PCR) 2.203 deg
Dedendum angle, DA = 57.3*ATAN(B / PCR) 2.548 deg
Gear pitch cone angle (from above) PCAg = (from above) 67.385 deg
Face angle, FA = PCAg - AA 65.182 deg
Cutting angle, CA = PCAg - DA 64.837 deg
Angular Addendum, Z = COS(PCAg/57.3)*AA 0.8472 deg
Pitch diameter (from above), D = (from above) 7.833 in
Outside diameter, OD = D + (2*Z) 9.528 in
Crown height, CH = (.5*OD) / TAN(FA/57.3) 2.203 in
Face width, FW = CP*2 1.047 in
Circular thickness, T = 1.57 / P 0.2617 in
Chordal thickness, TC = D*Sin((90/57.3)/N) 0.2617 in
This is the end of this spread sheet.
GEAR SPREADSHEET ANALYSIS-CONTENT
Copy write, © Gear Spreadsheet Analysis by John R Andrew, 25 Oct 2012

http://shopswarf.orconhosting.net.nz/spur.html

GOAL SEEK

Excel Workbook - new version Excel-97 2003 - old

When using Excel's Goal Seek, unprotect the spread When using Excel's Goa
sheet by selecting: Drop down menu: Home > Format > sheet by selecting: Drop
Unprotect Sheet > OK. When Excel's Protection > Unprotect S
Goal Seek is not needed, restore protection with: Goal Seek is not needed
Drop down menu: Format > Protect Sheet. Drop down menu: Form
GOAL SEEK METHOD-NEW GOAL SEEK METHOD-O
Step-1 Select cell containing a formula Step-1 Select cell contain
Step-2 Select: Data > What-If Analysis > Goal Seek Step-2 Select: Tools > Go
Step-3 To value: 14000, for example Step-3 To value: 14000, f
Step-4 Pick cell containing value to be changed by Excel > OK Step-4 Pick cell containin

Goal Seek Method Problem

Use this side to practice

Input
ADJ = 5.20
OPP = 3.00
Calculations
HYP = (ADJ^2 + OPP^2)^(1/2)
= 6.00

Step-1 Pick the cell containing a formula C58.

Step-2 Pick menu: Data > What-If Analysis > Goal Seek
Step-3 Pick> To Value: "6".
Step-4 By changing cell: Pick cell "C54"
 Excel's, Equation "Solver"
Excel's Solver can solve one equation of the form: y equals a function of x, y = f(x). The
function of x can be a polynomial; ( a + bx + cx2 + dx3 +…. zxn ), an exponential: ( aenx ), a
logarithmic: a(logx), trigonometric: ( aSin x + bCos x), or any other function of x.

Also Excel's Solver can solve multple simultaneous equations; linear, non-linear, or a mixture
of the two.

Excel iteratively adjusts one input value of x to cause one calculated formula cell value of y to
equal a target value of y.

C D
5 Problem
6 Guess X = 1.4
7
8 Y = 2*X^5 - 3*X^2 - 5
9 = -0.1235

Solver Example
1. The input value of X is 1.4 and this value of X causes Y to equal -0.1235 in the spreadsheet
table above.
2. Excel's Solver will adjust the input value of X, in this case1.4 in blue cell D6, by iteration
(repeatedly) until the calculated value of Y in the yellow cell D9 approaches the target value of
zero, ( 0 ).

3. Select the calculated answer in yellow cell, ( D9 ) below.

4. Select: Tools > Goal Seek > Target Cell [ $D$9 ] > Equal to: > Value of:
> 0 > By changing cells: Select [ $D$6 ] > Add (Constraints) >
Cell Reference > $D$9 = 0 > OK.

C D
5 Solution
6 Solved X = 1.4041
7
8 Y = 2*X^5 - 3*X^2 - 5
9 = 0.0004

5. The completed calculation above shows that if X = 1.4041 then Y = 0.0004 or

4 / 10,000 which is close enough to 0 for engineering purposes.
Excel-97 2003 - old version
When using Excel's Goal Seek, unprotect the spread
sheet by selecting: Drop down menu: Tools >
Protection > Unprotect Sheet > OK. When Excel's
Goal Seek is not needed, restore protection with:
Drop down menu: Format > Protect Sheet.
GOAL SEEK METHOD-OLD
Step-1 Select cell containing a formula
Step-2 Select: Tools > Goal Seek
Step-3 To value: 14000, for example
Step-4 Pick cell containing value to be changed by Excel > OK

Goal Seek Method

Example only

Input
ADJ = 5.20
OPP = 3.00
Calculations
HYP = (ADJ^2 + OPP^2)^(1/2)
= 6.00

Step-1 Pick the cell containing a formula C58.

Step-2 Pick menu: Data > What-If Analysis > Goal Seek
Step-3 Pick> To Value: "6".
Step-4 By changing cell: Pick cell "C54"
OPP^2)^(1/2)