Solutions to Chapter 11 Exercise Problems

Problem 11.1

Two helical gears are cut with a spur gear hob that has a diametral pitch of 4 and a pressure angle of
20˚. The pinion has 15 teeth, the gear has 35 teeth, and the helix angle is 30˚. Determine the minim
um recommended face width. Using the minimum face width, find the transverse diametral pitch, th
e pitch cylinder radii, and the axial, transverse, and total contact ratios.

Solution

The limiting condition for the face width is given by Eq. (11.15)

1.15pn
F

sin

The normal pitch is given by

pn =

Pn

Therefore,

F
1.15
Pn sin
Now
1.15
= 1.15
= 1.8064
Pn sin 4sin30

Therefore,

F
1.8064
The properties of the gears in the normal direction will be the same as those of the hob. The transve
rse diametral pitch (Pt ) for both gears is related to the normal diametral pitch by Eq. (11.5). Based
on the diametral pitch of the hob,
Pt = Pn cos
= 4cos30 = 3.464

The pitch cylinder diameters are related to the diametral pitch through Eq. (11.4) Therefore,

Dt = Nt
Pt
and the pitch cylinder radius for the pinion is

N2t
r2t = = 15 = 2.165 in
2Pt 2(3.464)

The pitch cylinder radius for the gear is

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 N3t
r3t = = 35 = 5.052 in
2Pt 2(3.464)

The transverse contact ratio is given by Eq. (11.16) as

pt (2 + 3)
mct =

cost
where
i =
rpi sin t + a2i + 2ai rpi + rp2i sin2 t , i = 2, 3

The addenda are determined by the hob. Because a standard hob is used, both addenda are given b
y
a = 1 = 1 = 0.25 inch
Pn 4

The transverse circular pitch is given by Eq. (11.3) as

pt =
=
= 0.907
Pt 3.464

and the transverse pressure angle is given by Eq. (11.7) as

 tann 
t = tan
1
 cos  (
cos30 )
= tan
1 tan 20 = 22.796˚

Now,
 2 =
rp2 sin t + a22 + 2a2 rp2 + rp22 sin2 t
=
2.165sin(22.796)+ (0.25)2 + 2(0.25)(2.165) + [2.165sin(22.796)]2 = 0.5208
and
3 =
rp3 sin t + a23 + 2a3rp3 + rp23 sin2 t
=
5.0518sin(22.796)+ (0.25)2 + 2(0.25)(5.0518) + [5.0518sin(22.796)]2 = 0.5764

Therefore, the transverse contact ratio is

pt (2 + 3) 0.907(0.5208 + 0.5764)

mct = = = 1.3123

cost
cos(22.796)

The axial contact ratio is given by Eq. (11.16) as

F tan
1.8064tan30
mca = = = 1.1500
pt 0.907

The total contact ratio is

mc = mct + mca = 2.4623+ 1.1500 = 2.4623

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Problem 11.2

Two helical gears are cut with the same tooth numbers and with the same cutter as given in Problem
11.1. The helix angle is 30˚. Find the transverse pressure angle, the transverse diametral pitch, and
the axial pitch.

Solution

The transverse pressure angle is given by Eq. (11.7) as

 tann  tan20˚ = tan
1(0.4203) = 22.79˚

(
tan t = tan
1 cos  = tan
1
cos30˚)
The transverse diametral pitch (Pt ) for both gears is related to the normal diametral pitch by Eq. (11.
5). Based on the diametral pitch of the hob,
Pt = Pn cos
= 4cos30 = 3.464

The axial pitch is given by Eq. (11.6). Then

pn
pa = =
=
= 1.5708
sin Pn sin 4sin30˚

Problem 11.3

Two parallel helical gears are cut with a 20˚ normal pressure angle and a 45˚ helix angle. They have
a diametral pitch of 12 in the normal plane and have 10 and 41 teeth, respectively. Find the transver
se pressure angle, transverse circular pitch, and transverse diametral pitch. Also determine the mini
mum face width, and using that face width, determine the total contact ratio.

Solution

The transverse pressure angle is given by Eq. (11.7) as

tann
t = tan
1 cos  = tan
1 tan 20˚ = tan
1(0.5147) = 27.24˚
( )
cos45˚

The transverse diametral pitch (Pt ) for both gears is related to the normal diametral pitch by Eq. (11.
5). Based on the diametral pitch of the hob,
Pt = Pn cos
= 12cos45 = 8.485

The transverse circular pitch is given by Eq. (11.3) as

pt =
=
= 0.3702
Pt 8.485

The limiting condition for the face width is given by Eq. (11.15)

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 1.15pn
F

sin

The normal pitch is given by

pn =

Pn

Therefore,

F
1.15
Pn sin

Now

1.15
= 1.15
= 0.4258

Pn sin 12sin 45

Therefore,

F
0.4258
The pitch cylinder diameters are related to the diametral pitch through Eq. (11.4) Therefore,

Dt = Nt
Pt
and the pitch cylinder radius for the pinion is

N2t
r2t = = 10 = 0.589 in
2Pt 2(8.485)

The pitch cylinder radius for the gear is

N3t
r3t = = 41 = 2.416 in
2Pt 2(8.485)

The transverse contact ratio is given by Eq. (11.16) as

pt (2 + 3)
mct =

cost
where
i =
rpi sin t + a2i + 2ai rpi + rp2i sin2 t , i = 2, 3

The addenda are determined by the hob. Because a standard hob is used, both addenda are given b
y
a = 1 = 1 = 0.08333 in
Pn 12

Now,

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  2 =
r2t sin t + a22 + 2a2 r2t + r22t sin2 t
=
0.589sin(27.24) + (0.08333)2 + 2(0.08333)(0.589) + [0.589sin(27.24)]2 = 0.1521
and
3 =
r3t sin t + a23 + 2a3r3t + r32t sin2 t
=
2.416sin(27.24) + (0.08333)2 + 2(0.08333)(2.416) + [2.416sin(27.24)]2 = 0.1719

Therefore, the transverse contact ratio is

pt (2 + 3) 0.3702(0.1521+ 0.1719)

mct = = = 0.9841

cost
cos(27.24)

The axial contact ratio is given by Eq. (11.16) as

F tan
0.4258tan 45
mca = = = 1.1500
pt 0.3702

The total contact ratio is

mc = mct + mca = 0.9841+ 1.1500 = 2.1341

Problem 11.4

A helical gear has 18 teeth and a transverse diametral pitch of 6. The face width is 1.5, and the helix
angle is 25˚. Determine the axial pitch, normal pitch, lead, transverse pitch diameter, and minimum
face width.

Solution

The transverse pressure angle is given by Eq. (11.7) as

tann
t = tan
1 cos   = tan
1 tan20˚ = tan
1(0.9063) = 21.88˚
( )
cos25˚

The transverse diametral pitch (Pt ) for the gear is related to the normal diametral pitch by Eq. (11.5)
. Based on the transverse diametral pitch
Pn = Pt / cos
= 6 / cos25 = 6.620

The transverse pitch diameter is given by

dt = N2 = 18 = 3
Pt 6

The transverse circular pitch is given by Eq. (11.3) as

pt =
=
= 0.5236
Pt 6

The axial pitch is given by Eq. (11.6). Then

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 pn
pa = =
=
= 1.1229
sin Pn sin 6.620sin25˚

The lead is given by Eq. (11.25) as

L = N2 pa = 18(1.1229) = 20.212 in

The limiting condition for the face width is given by Eq. (11.15)

1.15pn
F

sin

The normal pitch is given by

pn =

Pn

Therefore,

Fmin
1.15
Pn sin

Now

1.15
= 1.15
= 1.2913

Pn sin 12sin 45

Therefore,

Fmin
1.2913

Problem 11.5

Two helical gears have 20 and 34 teeth and a normal diametral pitch of 8. The left-handed pinion h
as a helix angle of 40˚ and a rotational speed of 1000 rpm. The gear is also left handed and has a h
elix angle of 40˚. Determine the angular velocity of the gear, transverse diametral pitch of each gear,
and pitch diameters.

Solution

The angular velocity of the gear is given by Eq. (11.11) as

2 = N3

3 N2

Then,

3 =
2 N2 = 1000 34 = 1700 rpm

N3 20

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The transverse diametral pitch (Pt ) for each gear is related to the normal diametral pitch by Eq. (11.
5). Then
Pt = Pn cos
= 8cos40 = 6.128

The pitch diameter for the pinion is given by

d2 = N2 = 20 = 3.263 in
Pt 6.128

And the pitch diameter for the gear is given by

N3 = 34 = 5.548 in
d3 =
Pt 6.128

Problem 11.6

Two standard spur gears have a diametral pitch of 10, a pressure angle of 20˚, and a velocity ratio eq
ual to 3.5:1. The center distance is 8.55 in. Two helical gears are to be used to replace the two spur
gears such that the center distance and angular velocity ratio remain unchanged. The helical gears a
re also to be cut with the same hob as that used to cut the spur gears. Determine the helix angle, too
th numbers, and minimum face width for the new gears if the helix angle is kept to a minimum.

Solution

For the helical gears, we need to determine the helix angle and the number of teeth on each gear. W
e will find the number of teeth and transverse diametral pitch first and then determine the helix angle
. The velocity ratio is given by Eq. (11.11) as

2 = rp3 = Dp3 = N3 / Pt = N3

3 rp2 Dp2 N2 / Pt N2

and the center distance is given by Eq. (11.12)

C = r2 + r3 = D2 + D3
2
For the spur gear,

d3 = N3 d2 = 3.5d2
N2
and
C = 8.55 = d2 + d3 = d2 + 3.5d2 = 4.5d2 = 2.25d2
2 2 2
Therefore,

d2 = 3.8 in
and
d3 = 3.5d2 = 13.3 in
Also,

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 N2 = Pnd2 = 10(3.8) = 38
and
N3 = Pn d3 = 10(13.3) = 133

The pitch radii for the helical gears must be the same as the corresponding radii for the spur gears.
However, the tooth numbers can and will be different. The transverse diametral pitch is related to t
he normal diametral pitch by

Pt = Pn cos
(11.5)

and to the teeth numbers by

Pt = N2 = N3 (11.19)
2rp2 2rp3

From Eq. (11.5), it is clear that Pt < Pn . Therefore, based on Eq. (11.19), the tooth numbers on the
helical gears must be less than those on the spur gears. As a result, when we investigate tooth numb
ers that satisfy Eq. (11.18), we need only consider values which are lower than the corresponding va
lues for the spur gears. A set of values is

N2 N3 = 3.5N2
38 133 (spur gear)
37 129.5
36 126

From the table, the first set of teeth numbers that are integers are N2 = 36 and N3 = 126. For these
numbers, the transverse pitch is given by Eq. (11.19) as

Pt = N2 = N3 = 36 = 126 = 9.474
2rp2 2rp3 2(1.8) 2(6.65)

From Eq. (11.5),

( )
 = cos
1 Pt  = cos
1 9.474 = 18.672˚
Pn 10

Notice that this is the lowest helix angle possible (other than 0) if the center distance and velocity rat
io are to be maintained. The minimum face width is given by Eq. (11.14):

1.15pt
F
or F
1.15
tan Pt tan

Therefore,

1.15
F
( 9.474tan(18.672) = 1.128 in )

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Problem 11.7

Two standard spur gears have a diametral pitch of 16 and a pressure angle of 20˚. The tooth numbe
rs are 36 and 100, and the gears were meshed at a standard center distance. After the gear reducer
was designed and tested, the noise of the drive was found to be excessive. Therefore, the decision w
as made to replace the spur gears with helical gears. The helix angle chosen was 22˚, and the tooth
numbers were to remain unchanged. Determine the change in center distance required.

Solution

The center distance for the spur gears is given by Eq. (11.12)

Cc = r2 + r3 = D2 + D3 = N2 + N3 = 36 + 100 = 4.25 in
2 2Pn 2(16)

For the helical gears,

Ch = dt 2 + dt3 = N2 + N3 = N2 + N3 = Cc = 4.25 = 4.583 in

2 2Pt 2Pn cos
cos
cos22

The change in center distance is given by

C = Ch  Cc = 4.583 4.25 = 0.333 in

Problem 11.8

A spur gear transmission consists of a pinion that drives two gears. The pinion has 24 teeth and a d
iametral pitch of 12. The velocity ratio for the pinion and one gear is 3:2 and for the pinion and the
other gear is 5:2. To reduce the noise level, all three gears are to be replaced by helical gears such t
hat the center distances and velocity ratios remain the same. The helical gears will be cut with a 16
pitch, 20˚ hob. If the helix angle is kept as low as possible, determine the number of teeth, face widt
h, hand, helix angle, and outside diameter for each of the gears.

Solution

Assume that the gear arrangement is as shown in the figure.

4 3
2

For the helical gears, we need to determine the helix angle and the number of teeth on each gear. W
e will find the number of teeth and transverse diametral pitch first and then determine the helix angle
. For the pinion,

- 439 -
 d2 = N2 = 24 = 2 in
Pn 12

The velocity ratio for the first gears is given by Eq. (11.11) as

2 = rp3 = dt3 = N3 / Pt = N3 = 3

3 rp2 dt2 N2 / Pt N2 2

Therefore,
N3 = 3 N2 = 3 24 = 36
2 2
and
dt3 = 3 dt2 = 3 (2) = 3 in
2 2

For the second gear,

2 = rp4 = dt4 = N4 / Pt = N4 = 5

4 rp2 dt2 N2 / Pt N2 2

Therefore,
N4 = 5 N2 = 5 24 = 60
2 2
and
dt4 = 5 dt2 = 5 (2) = 5 in
2 2
The center distances is given by Eq. (11.12). Then

C1 = r2 + r3 = dt2 + dt3 = 2 + 3 = 2.5 in

2 2
and
C2 = r2 + r4 = dt2 + dt 4 = 2 + 5 = 3.5 in
2 2
The pitch radii for the helical gears must be the same as the corresponding radii for the spur gears.
However, the tooth numbers can and will be different. The transverse diametral pitch is related to t
he normal diametral pitch by

Pt = Pn cos
(11.5)

and to the teeth numbers by

Pt = N2 = N3 (11.19)
2rp2 2rp3

From Eq. (11.5), it is clear that Pt < Pn . Therefore, based on Eq. (11.19), the tooth numbers on the
helical gears must be less than those on the spur gears. As a result, when we investigate tooth numb
ers that satisfy Eq. (11.18), we need only consider values which are lower than the corresponding va
lues for the spur gears. A set of values is

- 440 -
 N2 N4 = 1.5N2 N4 = 2.5N2
24 36 60(spur gear)
23 34.5 57.5
22 33 55

From the table, the first set of teeth numbers that are integers for the three gears are N2 = 22 and N3
= 33, and N4 = 55. For these numbers, the transverse pitch is given by Eq. (11.19) as

Pt = N2 = N3 = N4 = 22 = 33 = 55 = 11
2rp2 2rp3 2rp 4 2(1) 2(1.5) 2(2.5)

From Eq. (11.5),

Pn ( )
 = cos
1 Pt  = cos
1 11 = 46.567˚
16

Notice that this is the lowest helix angle possible (other than 0) if the center distance and velocity rat
io are to be maintained. The minimum face width is given by Eq. (11.14):

1.15pt
F
or F
1.15
tan Pt tan

Therefore,

1.15
F
(11tan(46.567) = 0.311 in)

The blank diameters of the three gears are given by

do2 = dp2 + 2a2 = dp2 + 2 k = 2 + 2 1 = 2.125 in ,

Pn 16

do3 = d p3 + 2a3 = d p3 + 2 k = 3+ 2 1 = 3.125 in

Pn 16
and
do4 = dp4 + 2a4 = dp 4 + 2 k = 5 + 2 1 = 5.125 in
Pn 16

The hand of the gears is arbitrary; however, the pinion will be one hand and the two gears will be th
e opposite hand. For example, if the pinion is right handed, gears 3 and 4 will be left handed.

Problem 11.9

A pair of helical gears have a module in the normal plane of 3 mm, a normal presure angle of 20˚, an
d a helix angle of 45˚. The gears mesh with parallel shafts and have 30 and 48 teeth. Determine the
transverse module, the pitch diameters, the center distance, and the minimum face width.

- 441 -
Solution

The transverse pressure angle is given by Eq. (11.7) as

tann
t = tan
1 cos   = tan
1 tan 20˚ = tan
1(0.5147) = 27.24˚
( )
cos45˚

The transverse module (mt ) for both gears is related to the normal module by

mt = dt = mn = 3 = 4.243 mm
N cos
cos45

The transverse pitch diameters are

dt2 = N2 mt = 30(4.243) = 127.28 mm

and
dt3 = N3 mt = 48(4.243) = 203.66 mm

The center distance is given by

C = r2 + r3 = dt2 + dt3 = 127.28 + 203.66 = 165.47 mm

2 2
The limiting condition for the face width is given by Eq. (11.15)

1.15pn 1.15mn
F
 sin = sin = 1.15
 3 = 15.328 mm 
sin 45 

Problem 11.10

Two 20˚ spur gears have 36 and 90 teeth and a module of 1.5. The spur gears are to be replaced by
helical gears such that the center distance and velocity ratio are not changed. The maximum allowe
d face width is 12.7 mm, and the hob module is 1.5 mm. Design the helical gear pair that has the s
mallest helix angle possible. Determine the numbers of teeth, the face width, the helix angle, and the
outside diameters of the gears.

Solution

For the helical gears, we need to determine the helix angle and the number of teeth on each gear. W
e will find the number of teeth and transverse diametral pitch first and then determine the helix angle
. The velocity ratio is given by Eq. (11.11) as

2 = rp3 = dp3 = N3 / Pt = N3 = 90 = 2.5 (1)

3 rp2 d p2 N2 / Pt N2 36

and the center distance is given by Eq. (11.12)

C = r2 + r3 = d2 + d3
2
For the spur gear,

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 d2 = N2m = 36(1.5) = 54 mm , (2)

d3 = N3m = 90(1.5) = 135 mm , (3)

Assume that full depth gears are used. Then the addendum length is given by

a = 1 = mn
Pn

The outside diameter of the gears are given by

do2 = d2 + 2mn = 54 + 2(1.5) = 57 mm

and

do3 = d3 + 2mn = 135+ 2(1.5) = 138 mm

The center distance is given by

54 + 135
C = d2 + d3 = = 94.5 mm
2 2 (4)

The pitch radii for the helical gears must be the same as the corresponding radii for the spur gears.
However, the tooth numbers can and will be different. The transverse module is related to the norm
al module by

mt = mn / cos
(5)

and to the teeth numbers by

mt = dt2 = dt3 (6)

N2 N3

From Eq. (5), it is clear that mt > mn . Therefore, based on Eq. (6), the tooth numbers on the helical
gears must be less than those on the spur gears. As a result, when we investigate tooth numbers tha
t satisfy Eq. (1), we need only consider values which are lower than the corresponding values for th
e spur gears. A set of values is

N2 N3 = 2.5N2
36 90 (spur gear)
35 87.5
34 85
33 82.5
32 80
31 77.5
30 75

From the table, the first set of teeth numbers that are integers are N2 = 34 and N3 = 85. For these n
umbers, the transverse module is given by

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 d p2 dp3 54
mt = = = = 1.588 mm
N2 N3 34

From Eq. (5), the helix angle is given by

( )
 = cos
1 mn  = cos
1 1.5 = 19.19˚
mt 1.588

Notice that this is the lowest helix angle possible (other than 0) if the center distance and velocity rat
io are to be maintained. The minimum face width is given by

F
1.15 t
m
tan

Therefore,

1.15mt 1.151.588
F
 tan = tan(19.19) = 16.486 mm

This exceeds the maximum allowed face width of 12.7 mm. Therefore, we must try the next lower v
alues for the tooth numbers. These are N2 = 32 and N3 = 80. For these numbers, the transverse m
odule is given by

d p2 dp3 54
mt = = = = 1.688 mm
N2 N3 32

From Eq. (5), the helix angle is given by

( )
 = cos
1 mn  = cos
1 1.5 = 27.266˚
mt 1.688

The minimum face width is given by

 1.15mt 1.15 1.688 

F
 tan = tan(27.266) = 11.833 mm

Problem 11.11

Two helical gears are cut with a 20˚ hob with a module of 2. One gear is right handed, has a 30˚ hel
ix angle, and has 36 teeth. The second gear is left handed, has a 40˚ helix angle, and has 72 teeth.
Determine the shaft angle, the angular velocity ratio, and the center distance.

Solution

The shaft angle is given by Eq. (11.21). Then,

 =  2 ±  3 = 30˚
40˚=
10˚

The angular velocity of the gear is given by Eq. (11.11) as

- 444 -

2 = N3

3 N2

Then,

3 = N2 = 36 = 2

2 N3 72

The pitch diameter for gear 2 is given by

dt2 = N2 mn = 36(2) = 83.14 mm

cos
cos(30)

and for gear 3,

dt2 = N2 mn = 72(2) = 187.98 mm

cos
cos(40)

The center distance is

C = r2 + r3 = d2 + d3 = 83.14 +187.98 = 135.56 mm

2 2

Problem 11.12

Two crossed shafts are connected by helical gears such that the velocity ratio is 3:1, and the shaft an
gle is 60˚. The center distance is 10 in, and the normal diametral pitch is 8. The pinion has 35 teeth
. Assume that the gears are the same hand and determine the helix angles, pitch diameters, and reco
mmended face widths.

Solution

The velocity ratio is given by

2 = N3 = 3

3 N2

Therefore,

N3 = 3N2 = 3(35) = 105

The pitch diameters for the two gears are given by

d p2 = N2 = N2 (1)
Pt2 Pn cos
2
and
d p3 = N3 = N3 (2)
Pt3 Pn cos
3

The center distance is

- 445 -
 d2 + d3 = 1  N2 + N3  = 10 in
C = r2 + r3 =
2 2Pn  cos
2 cos
3 
Or,
N2 + N3 = 10(2)P
n
cos
2 cos
3
and
35 + 105 = 2(10)(8) = 160 (3)
cos
2 cos
3

Both gears are of the same hand. Therefore, the shaft angle is given by

=  2 +  3 = 60˚ (4)

To find the helix angles, we must solve Eqs. (3) and (4) simultaneously. First use Eq. (4) to solve f
or
2 in terms of
3 . Then substitute the result into Eq. (3). This gives

35 + 105 = 160
cos(60
 3) cos 3

This equation can be solved iteratively for
3 using MATLAB. The result is

2 = 32.298˚
and

3 = 27.702˚

The pitch diameters are given by

d p2 = N2 = 35 = 5.176 in
Pn cos
2 8cos(32.298˚)
and
N2 = 105
d p3 = = 14.182 in
Pn cos
3 8cos(27.702˚)

The minimum face width for each gear is given by

1.15pn
F
 sin = P1.15
 
n sin 

Then,

1.15 1.15
[
F2
P sin = 8sin(32.298˚) = 0.845 in
n 2 ]
and

1.15 1.15
[
F3
P sin = 8sin(27.702˚) = 0.971in
n 3 ]
The recommended face widths would be 0.85 in and 1.00 in for gears 2 and 3, respectively.

- 446 -
Problem 11.13

Two crossed shafts are connected by helical gears such that the velocity ratio is 3:2, and the shaft an
gle is 90˚. The center distance is 5 in. Select a pair of gears that will satisfy the design constraints.
What other information might be considered to reduce the number of arbitrary choices for the desi
gn?

Solution

To complete the design, we need to select diametral pitch for the hob used to cut the gears and the n
umber of teeth on one of the gears. We also need to identify if both gears are the same hand or opp
osite hand.

Initially assume that the helix angles on the gears are the same hand. Also select a hob with a diame
tral pitch of 12 and assume that the pinion has 30 teeth. If these values do not give helix angles whi
ch are approximately equal, we can select other values.

The velocity ratio is given by

2 = N3 = 3 = 1.5

3 N2 2

Therefore,

N3 = 1.5N2 = 1.5(30) = 45

The pitch diameters for the two gears are given by

d p2 = N2 = N2 (1)
Pt2 Pn cos
2
and
d p3 = N3 = N3 (2)
Pt3 Pn cos
3

The center distance is

d2 + d3 = 1  N2 + N3  = 5 in
C = r2 + r3 =
2 2Pn  cos
2 cos
3 
Or,
N2 + N3 = 5(2)P
n
cos
2 cos
3
and
30 + 45 = 2(5)(12) = 120 (3)
cos
2 cos
3

Assume that both gears are of the same hand. Therefore, the shaft angle is given by

=  2 +  3 = 90˚ (4)

To find the helix angles, we must solve Eqs. (3) and (4) simultaneously. First use Eq. (4) to solve f
or
2 in terms of
3 . Then substitute the result into Eq. (3). This gives

- 447 -
 30 + 45 = 120
cos(90
 3) cos 3

This equation can be solved iteratively for
3 using MATLAB. The result is

-0.00001 32.149 57.851 2.953 7.047 0.566 0.356

2 = 32.149˚
and

3 = 57.851˚

The pitch diameters are given by

d p2 = N2 = 30 = 2.953 in
Pn cos
2 12cos(32.149˚)
and
N2 = 30
d p3 = = 7.047 in
Pn cos
3 12cos(57.851˚)

The minimum face width for each gear is given by

1.15pn
F
 sin = P1.15
 
n sin


Then,

1.15 1.15
[
F2
P sin = 12sin(32.149˚) = 0.566 in
n 2 ]
and

1.15 1.15
[
F3
P sin = 12sin(57.851˚) = 0.356 in
n 3 ]
The recommended face widths would be 0.60 in and 0.40 in for gears 2 and 3, respectively.

To reduce the number of arbitrary choices we could specify limits on the helix angles or on the toot
h numbers. Also, we have not considered strength yet. The stress and wear equations for the gear t
eeth will add additional constraints.

Problem 11.14

A helical gear with a normal diametral pitch of 8 is to be used to drive a spur gear at a shaft angle of
45˚. The helical gear has 21 teeth, and the velocity ratio is 2:1. Determine the helix angle for the he
lical gear and the pitch diameter of both gears.

Solution

The helix angle for the spur gear is 0; therefore, the helix angle for the helical gear must be the same
as the shaft angle or 45˚. Both gears must have the same normal diametral pitch. The helical gear i
s the pinion (gear 2) and the gear is gear 3.

- 448 -
The velocity ratio is given by

2 = N3 = 3 = 1.5

3 N2 2

Therefore,

N3 = 2N2 = 2(21) = 42

The pitch diameters for the two gears are given by

d p2 = N2 = N2 = 21 = 3.712 in (1)
Pt2 Pn cos
2 Pn cos45
and
d p3 = N3 = N3 = 41 = 5.125 in (2)
Pt3 Pn cos
3 8cos0

Problem 11.15

Two crossed helical gears connect shafts making an angle of 45˚. The pinion is right handed, has a
helix angle of 20˚, and contains 30 teeth. The gear is also right handed and contains 45 teeth. The t
ransverse diametral pitch of the gear is 5. Determine the pitch diameter, the normal pitch, and the le
ad for each gear.

Solution

Because both gears are of the same hand, the relationship between the helix angles and shaft angle i
s

=  2 +  3 = 45˚

Therefore,

 3 = 45˚
 2 = 45˚
20˚= 35˚

The pitch diameters for the gear is given by

d p3 = N3 = 45 = 9 in
Pt3 5

and the normal diametral pitch for both gears is

Pn = Pt3 = 5 = 6.104
cos
3 cos35˚

The normal pitch is given by

pn =
=
= 0.515 in
Pn 6.104

This is a nonstandard pitch and would require a special hob. The pitch diameter for the pinion is

- 449 -
 d p3 = N3 = N3
Pt3 Pn cos
3

The pitch diameters are given by

N2 = 30
d p2 = = 5.230 in
Pn cos
2 6.104cos(20˚)

The axial pitches for the two gears are

pn
pa2 = = 0.515 = 1.505 in
sin
2 sin(20˚)
and
pn
pa3 = = 0.515 = 0.897 in
sin
3 sin(35˚)

The leads for the two gears are

L2 = N2 pa2 = 30(1.505) = 45.15

and
L3 = N3 pa3 = 45(0.897) = 40.365

Problem 11.16

The worm of a worm gear set has 2 teeth, and the gear has 58 teeth. The worm axial pitch is 1.25 in
, and the pitch diameter is 3 in. The shaft angle is 90˚. Determine the center distance for the two ge
ars, the helix angle, and the lead for the worm.

Solution

Because the shaft angle is 90˚, the transverse circular pitch of the gear is equal to the axial pitch of t
he worm. Therefore,

pt 3 = 1.25

Therefore, the pitch diameter of the gear is

pt3N3 1.25(58)
dt3 = = = 23.078 in



The center distance is

C = r2 + r3 = d2 + d3 = 3+ 23.078 = 13.039 in
2 2
To determine the helix angles, use the relationships for the shaft angle and angular velocity ratio. B
ecause both gears are of the same hand, the relationship between the helix angles and shaft angle is

=  2 +  3 = 90˚ (1)

The angular velocity ratio is

- 450 -
 2 = N3 = dt3 cos
3 = dt3 cos
3
3 N2 dt 2 cos
2 dt2 cos
2

Then,

58 = 23.078cos
3
2 3cos
2

and

cos
2 = 0.26526cos
3 (2)

Combining Eqs. (1) and (2),

cos(90
 3)
0.26526cos 3 = 0 (3)

Equation (3) can be solved iteratively for
3 by using MATLAB. The result is

2 = 75.144˚
and

3 = 14.856˚

The lead for the worm is given by

L2 = N2 pa2 = 2(1.25) = 2.5

Problem 11.17

The shaft angle between two shafts is 90˚, and the shafts are to be connected through a worm gear s
et. The center distance is 3 in, and the velocity ratio is 30:1. Determine a worm and gear that will sa
tisfy the design requirements. Specify the number of teeth, lead angle, and pitch diameter for each g
ear. Also, determine the face width for the gear.

Solution

This problem has considerable design latitude. We need to satisfy only three equations. One equat
ion is for the shaft angle

=  2 +  3 = 90˚

The second is for the velocity ratio

2 = N3 = dt3 cos
3 = dt3 cos
3

3 N2 dt 2 cos
2 dt2 cos
2

and the third is for the center distance

- 451 -
  
C = rt2 + rt 3 = N2 + N3 = N2 + N3 = 1  N2 + N3 
2Pt2 2Pt3 2Pn cos
2 2Pn cos
3 2Pn  cos
2 cos
3 

We can rewrite the equations in terms of the helix angles, tooth numbers, and normal diametral pitc
h. Doing this and substituting for the known variables,

2 +
3 = 90˚ (1)

N3 30
= (2)
N2 1

1  N2 + N3  = 3 (3)
2Pn  cos
2 cos
3 

This gives us three equations in five unknowns. Therefore, we must select values for two of the vari
ables. Let us choose N2 = 2 and Pn = 12. Then from Eq. (2),

N3 = 30N2 = 30(2) = 60

Equations (1) and (2) can then be combined as

1  N2 + N3  = 1  2 + 60 = 3

2Pn  cos 2 cos 3  2(12)  cos(90
 3) cos 3 
or
2 + 60 = 3(2)(12) = 72 (4)
cos(90
 3) cos 3

Equation (4) can be solved iteratively using MATLAB. The result is

2 = 79.504
and

3 = 10.496

The pitch diameter of the gear is

pt3N3 1.25(58)
dt3 = = = 23.078 in



The center distance is

C = r2 + r3 = d2 + d3 = 3+ 23.078 = 13.039 in
2 2
To determine the helix angles, use the relationships for the shaft angle and angular velocity ratio. B
ecause both gears are of the same hand, the relationship between the helix angles and shaft angle is

=  2 +  3 = 90˚ (1)

The angular velocity ratio is

- 452 -
 2 = N3 = dt3 cos
3 = dt3 cos
3
3 N2 dt 2 cos
2 dt2 cos
2

Then,
58 = 23.078cos
3
2 3cos
2
and
cos
2 = 0.26526cos
3 (2)

Combining Eqs. (1) and (2),

cos(90
 3)
0.26526cos 3 = 0 (3)

Equation (3) can be solved iteratively for
3 by using MATLAB. The result is

2 = 79.504
and

3 = 10.496

The transverse pitch diameters are

dt2 = N2 2
= = 0.457 in
2Pn cos
2 2(12)cos(79.504)
and
N3 60
dt3 = = = 2.543 in
2Pn cos
3 2(12)cos(10.496)

The lead for the worm and gear are

N2 pn
L2 = N2 pa2 = = N2
= 2
= 0.532
sin 2 Pn sin 2 12sin(79.504)
and
N3 pn
L3 = N3 pa3 = = N3
= 2
= 2.874
sin 3 Pn sin 3 12sin(10.496)

The minimum facewidth for the gear is given by

1.15pn
F
 sin = P1.15
 
n sin 
Then,
1.15 1.15
[
F3
P sin = 12sin(10.496˚) = 1.653 in
n 3 ]
For this type of gear, the minimum facewidth is not very meaningful. The worm contacts the gear at
one point only, so the entire face is not contacted.

- 453 -
Problem 11.18

A worm with two teeth drives a gear with 50 teeth. The gear has a pitch diameter of 8 in and a helix
angle of 20˚. The shaft angle between the two shafts is 80˚. Determine the lead and pitch diameter
of the worm.

Solution

The normal diametral pitch for the gears is

N3 50
Pn = = = 3.326
2dt3 cos
3 2(8)cos20˚

The shaft angles for the two gears are related by

=  2 +  3 = 80˚

Therefore,

 2 = 80˚
 3 = 80˚
20˚= 60˚

The pitch diameter of the worm is then given by

dt2 = N2 2
= = 0.601 in
2Pn cos
2 2(3.326)cos(60)

The lead for the worm is

N2 pn
L2 = N2 pa2 = = N2
= 2
= 2.181
sin 2 Pn sin 2 3.326sin(60)

Problem 11.19

Two straight-toothed bevel gears mesh with a shaft angle of 90˚ and a diametral pitch of 5. The pini
on has 20 teeth, and the gear ratio is 2:1. The addendum and dedendum are the same as for 20˚ stu
b teeth. For the gear, determine the pitch radius, cone angle, outside diameter, cone distance, and fac
e width.

Solution

The number of teeth on the gear is given by

N3 = N2
2 = 20 2 = 40

3 1

The pitch cone angle for the gear is given by Eq. (11.27). Then,
N
[ ]
 3 = tan
1 N3 = tan
1(2) = 63.435˚
2

- 454 -
The pitch cone angle for the pinion is given Eq. (11.31). Then,

 2 = 
 3 = 90˚
63.435˚= 26.565˚

The pitch radius for the large end of the gear is given by

r3 = N3 = 40 = 4
2Pn 2(5)

The cone distance is given by

d2 = d3 = r3 = 4
ro = = 4.472 in
2sin
2 2sin
3 sin
3 sin(63.435)

The outside diameter at the back of the gear is

do3 = d3 + 2a = d3 + 2 k = 4 + 2 0.8 = 4.32 in

Pn 5

The face width limit is given by Eq. (11.43). Then

F < [0.3ro = 0.3(4.472) = 1.342]

or

F < 10 [
= 10 = 2
Pn 5 ]
We should use the smaller value for F or

F = 2 in

Problem 11.20

A pair of straight-toothed bevel gears mesh with a shaft angle of 90˚ and a diametral pitch of 6. The
pinion has 18 teeth, and the gear ratio is 2:1. The addendum and dedendum are the same as for 20˚
full-depth spur-gear teeth. Determine the number of teeth on the gear and the pitch diameters of bo
th the pinion and gear. Also, for the gear, determine the pitch-cone angle, outside diameter, cone dis
tance, and face width.

Solution

The number of teeth on the gear is given by

N3 = N2
2 = 18 2 = 36

3 1

The pitch cone angle for the gear is given by Eq. (11.27). Then,
N
[ ]
 3 = tan
1 N3 = tan
1(2) = 63.435˚
2

- 455 -
The pitch-cone angle for the pinion is given Eq. (11.31). Then,

 2 = 
 3 = 90˚
63.435˚= 26.565˚

The pitch diameter for the large end of the gear is given by

d3 = N3 = 36 = 6 in
Pn (6)

The pitch diameter for the pinion is given by Eq. (11.32). Then

d2 = d3 N2 = 6 18 = 3in
N3 36

The cone distance is given by

d2 = d3 = r3 = 3
ro = = 3.354 in
2sin
2 2sin
3 sin
3 sin(63.435)

The outside diameter at the back of the gear is

do3 = d3 + 2a = d3 + 2 k = 6 + 2 1 = 6.333 in
Pn 6

The face width limit is given by Eq. (11.43). Then

F < [0.3ro = 0.3(3.354) = 1.006]

and
F < 10 [
= 10 = 1.666
Pn 6 ]
We should use the smaller value for F or

F = 1in

Problem 11.21

A pair of straight-toothed bevel gears mesh with a shaft angle of 80˚ and a diametral pitch of 7. The
pinion has 20 teeth and a pitch cone angle of 40˚. The gear ratio is 3:2. Determine the number of t
eeth on the gear and the pitch diameters of both the pinion and gear. Also, determine the equivalent
spur gear radii for both the pinion and the gear.

Solution

The number of teeth on the gear is given by

N3 = N2
2 = 20 3 = 30

3 2

The pitch cone angle for the gear is given by Eq. (11.31).

- 456 -
  3 = 
 2 = 80˚
40˚= 40˚

The pitch diameter for the large end of the pinion is given by

d2 = N2 = 20 = 2.857 in
Pn 7

and for the gear,

N3 = 30 = 4.286 in
d3 =
Pn 7

The equivalent spur gear radius for the pinion is given by Eq. (11.39) as
d2 = 2.857 = 1.865 in
re2 =
2cos
2 2cos(40)

and for the gear,

d3 = 4.286 = 2.797 in
re3 =
2cos
3 2cos(40)

Problem 11.22

A pair of straight-toothed bevel gears mesh with a shaft angle of 45˚ and a module of 5.08. The pin
ion has 16 teeth and a pitch cone angle of 20˚. The gear ratio is 3:2. Determine the number of teeth
on the gear and the pitch diameters of both the pinion and gear. Also determine the back-cone dist
ance and the back-cone angle for the gear.

Solution

The number of teeth on the gear is given by

N3 = N2
2 = 16 3 = 24

3 2

The pitch cone angle for the gear is given by Eq. (11.31).

 3 = 
 2 = 45˚
20˚= 25˚

The pitch diameter for the large end of the pinion is given by

d2 = N2mn = 16(5.08) = 81.28 mm

and for the gear,

d3 = N3mn = 24(5.08) = 121.92 mm

The back-cone radius for the gear is given by Eq. (11.39) as

- 457 -
 d3 = 121.92 = 79.58 mm
re3 =
2cos
3 2cos(40)

The back-cone angle is given by

r 121.92
( ) [ ]
 = 2sin
1 r3 = 2sin
1 2(79.58) = 100˚
e3

- 458 -