Bevel Gears

Ques: - State and explain the following terms with suitable sketch: Pitch cone distance, Back
cone, Pitch cone angle (FEB 17 INSEM)
A bevel gear is in the form of the frustum of a cone.
The dimensions of a bevel gear are illustrated in
following figures (a) and (b).
1) Pitch Cone Distance: Cone distance is the
length of pitch-cone
cone element. It is also called
pitch-cone radius. It is denoted
ed by AO.
2) Pitch Cone: Pitch cone is an imaginary cone,
the surface of which contains the pitch lines of
all teeth in the bevel gear.
3) Back Cone: The back cone is an imaginary cone
and its elements are perpendicular to the elements
of the pitch cone.
4) Face Angle: It is the angle subtended by the face
of the tooth at the cone center.
Face angle = pitch angle + addendum angle = γ + α

Ques: - With neat sketch, explain the force analysis of bevel gears. (DEC. 15/16, MAY 13/17)
In force analysis, it is assumed that the resultant tooth force between two meshing teeth of a pair of
bevel gears is concentrated at the midpoint along the face width of the tooth. This is illustrated in
following figure (a), where the resultant force P, shown by dotted line, acts at the midpoint D of the
face width of the pinion. The resultant force has following three components:
Pt = tangential or useful component (N)
Pr = radial component (N)
Pa = axial or thrust component (N)

Consider a plane ABCD shaded by dots in Fig. (a) and again shown in Fig. (b). From triangle BCD,
tan α = = ………….(a)
Where, Pt = separating component (N)
α = pressure angle (degrees)
From (a), Ps = Pt tan a ……………..(b)
Consider the plane DEAF shown in Fig. (c). from triangle ADF,
Pr = Ps cos γ and Pa = Ps sin γ
Here the resultant force is act at mid-point of face width, therefore consider mid point radius for the
force analysis. The mean radius rm where the resultant force acts is given by,
rm = (𝐴𝐶 ) + (𝐴𝐵 ) …………..(c)
𝐴𝐶 = ………….(d)

( ⁄ )
= sin 𝛾 or 𝐴𝐵 = sin 𝛾 …….. (e)
From (c), (d) and (e),
rmp = −

rmg = −
Force components on pinion: The magnitudes are determined by using the following five
equations,
60 × 10 (𝑘𝑊)
𝑀 =
2𝜋𝑛
𝑴𝒕
𝑷𝒕 =
𝒓𝒎𝒑

𝑷𝒓 = 𝑷𝒕 × 𝒕𝒂𝒏 𝜶 × 𝐜𝐨𝐬 𝜸
𝑷𝒂 = 𝑷𝒕 × 𝒕𝒂𝒏 𝜶 × 𝐬𝐢𝐧 𝜸
Note that the notations Pt, Pr and Pa are used for components of force on pinion only.
As seen in following figure (c), the radial component on the gear is equal to the axial component (P a)
on the pinion. Similarly, the axial component on the gear is equal to the radial component (P r) on the
pinion.

Force Analysis
Force components on gear:
Tangential Component for gear = Tangential Component for pinion
Radial component of gear = Axial component of pinion
Axial component of gear = Radial component of pinion
The directions of tangential and radial components acting on pinion and gear are decided by same
method that is used for spur gears.
Ques: - Derive an expression for beam strength of straight bevel gears. (DEC. 13/18, MAY 12,
FEB. 15 INSEM)
What is bevel factor? Explain the significance of the same. (MAY 19)
The size of the cross-section of the tooth of a bevel gear varies along the face width, as shown in Fig.
In order to determine the beam strength of the tooth of a bevel gear, it is considered to be equivalent to
a formative spur gear in a plane perpendicular to the tooth element. Consider an elemental section of
the tooth at a distance x from the apex 0 and having a width dx. Applying the Lewis equation to a
formative spur gear at a distance x from the apex,
𝛿(𝑆 ) = 𝑚 𝑏 𝜎 𝑌 …… (a)
where, (Sb) = beam strength of the elemental section (N)
mx = module of the section (mm)
bX = face width (mm)
Y = Lewis form factor based on virtual number of teeth.
From the figure,
= ….…(b)

Beam Strength of Bevel Gear Tooth

At the element section, 𝑚 = = ….(c)

At the large end of the tooth, 𝑚 = …….(d)

From (c) and (d), 𝑚 =𝑚 …. (e)

Also, 𝑏𝑚 = 𝑑𝑥 ……(f)
Substituting (e) and (f) in (a), we have
𝛿(𝑆 ) = ……..(g)

From (b) and (g),∫[𝑟 𝛿(𝑆 )] = ∫ 𝑥 𝑑𝑥 …….(h)

The left hand side indicates the torque 𝑀
𝑀 = ∫( )
𝑥 𝑑𝑥

𝑀 =
( )

𝑀 = 𝑚𝑏𝜎 𝑌𝑅 1 − + ……(i)
Assuming beam strength (Sb) as the tangential force at the large end of tooth
𝑀 =𝑆 𝑅 …….(j)
From (h) and (j) , 𝑆 = 𝑚𝑏𝜎 𝑌 1 − +
The face width of the bevel gear is limited to one-third of the cone distance. Therefore, the last term
in the bracket will never be more than (1/27) neglecting the last term,

𝒃
𝑺𝒃 = 𝒎𝒃𝝈𝒃 𝒀 𝟏 −
𝑨𝟎
where, Sb = beam strength of the tooth (N)
m = module at the large end of the tooth (mm)
b = face width (mm)
σb = permissible bending stress (Sut /3) (N/mm2)
Y = Lewis form factor based on formative number of teeth
A0 = cone distance (mm)
1− is called the bevel factor.

Bevel Factor:- Lewis Equation for bevel gear is

𝒃
𝑺𝒃 = 𝒎𝒃𝝈𝒃 𝒀 𝟏 −
𝑨𝟎
where, 1 − is called the bevel factor.
The face width of the bevel gear is generally taken as 10 × 𝑚 𝑜𝑟 (𝐴 /3), whichever is smaller.
Ques: - Obtain the expression for ratio factor used in wear strength equation of bevel gear.(MAY
17)
Wear Strength for Bevel gear,
𝟎. 𝟕𝟓𝒃𝑸𝑫𝒑 𝑲
𝑺𝒘 =
𝐜𝐨𝐬 𝜸
Above equation is known as Buckingham's equation for the wear strength of bevel gears. The
equation is derived for the formative pair of pinion and gear. The ratio factor Q is, therefore, given
′
by, 𝑄 = ′ ′ ……..(d)

𝑉𝑖𝑟𝑡𝑢𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝑃𝑖𝑛𝑖𝑜𝑛; 𝑧 ′ = 𝑎𝑛𝑑

𝑧
𝑉𝑖𝑟𝑡𝑢𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝐺𝑒𝑎𝑟; 𝑧 ′ =
cos 𝛽
𝜋 𝜋
𝐵𝑢𝑡; 𝛾 + 𝛽 = ⇒𝛽= − 𝛾
2 2
 𝜋
cos 𝛽 = cos − 𝛾 = sin 𝛾
2
𝑧
𝑉𝑖𝑟𝑡𝑢𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 𝐺𝑒𝑎𝑟; 𝑧 ′ =
sin 𝛾
Substituting these values in eq. (d),
2 𝑧′ 2× 2×𝑧
𝑄= = =
𝑧′ + 𝑧′ + 𝑧 +
×

𝟐 𝒛𝒈
𝑸=
𝒛𝒈 + 𝒛𝒑 𝒕𝒂𝒏𝜸

Ques: - Compare straight bevel, spiral bevel and hypoid gears with sketch(DEC 11)
Differentiate between spiral bevel and hypoid bevel gears with sketch(MAY 15/16)
Classify bevel gears. State advantages and limitations of each type(DEC 16)

Straight Bevel Gear: -

The elements of the teeth of the straight bevel gears are straight
lines, which converge into a common apex point. Straight bevel
gears are easy to design and manufacture and give reasonably good
service when properly mounted on shafts. However, they create
noise at high
high-speed conditions.

Hypoid Gears
Gears: -
Hypoid gears are similar to spiral bevel gears that are mounted on
shafts, which are non-parallel and non-intersecting.
Hypoid gears have following characteristics:
(i) Hypoid gears have curved teeth.
(ii) Hypoid gears are mounted on non-parallel
parallel and non-
non
intersecting shafts.
Hypoid bevel gears are mainly used in automobile differentials. These gears allow the drive shaft to be
placed well below the centre line of the rear axle and thereby lower the centre of gravity of vehicle.
Another advantage of hypoid gears is that the offset of the shaft is so great that the shaft may continue
past each other. Hypoid gears give noiseless operation even at high sspeeds.
Ques: - What are the advantages and disadvantages of straight bevel gears? (MAY 11 DEC.18)
Advantages: -
1) Straight bevel gears are easy to design and manufacture and
2) Gives reasonably
easonably good service when properly mounted on shafts.
3) In straight bevel gears, the thrust load on bearings is less.
4) The straight bevel gears are least expensive
Disadvantage: -
1) Create noise at high-speed
speed conditions.
2) Due to sudden line contact the dynamic load is high
3) The straight bevel gears are not suitable for pitch line vvelocity above 5 m/s.
 4) In straight bevel gears contact ratio is low
5) In the straight bevel gears, the minimum number of the teeth require to avoid the interference is
relatively more; hence,, the arrangement is not compact.
Ques: - What are the advantages and disadvantages of spiral bevel gears? (MAY 11)
Advantages: -
1. There is a gradual contact between mating teeth. This results in smooth and quiet operation.
2. The spiral bevel gears have more load carrying capacity because more teeth are in contact
simultaneously and there is a greater arc of contact.
3. Spiral bevel gears permit higher operational speeds.
4. The spiral bevel gears are used where high speeds are enco
encountered.
Disadvantage: -
1) The analysis of forces in spiral gears is difficult compared with straight tooth bevel gears because
a number of parameters are involved such as hand of spiral for pinion as well as for gear and
direction of rotation for pinion.
Ques: - State the advantages of hypoid gears over the spiral bevel gears. (DEC. 13/18)
1) Hypoid bevel gears are mainly used in automobile differentials.
2) These gears allow the drive shaft to be placed well below the centerline of the rear axle and
thereby lower the centre of gravity of the vehicle.
3) Hypoid
ypoid gears are that the offset of the shaft is so great that the shafts may continue past each
other. Therefore, multiple power take
take-offs
offs from a single shaft with several pinions is possible.
4) Hypoid gears give noiseless operation even at high speeds.
Ques: - Difference between hypoid gears and the spiral bevel gears.
Spiral Bevel Gear Hypoid Gear

The elements of the teeth of the spiral bevel gears Hypoid gears are similar to spiral bevel gears
are spiral curves, which also converge into a that are mounted on shafts, which are non-
common apex point. parallel and non-intersecting
intersecting Hypoid gears are
Spiral bevel gears, on the other hand, are difficult based upon pitch surfaces, which are
to design and costly to manufacture, for they hyperboloids of revolution. Hypoid gears have
require specialized and sophisticated machinery following characteristics:
for their manufacturing. Spiral bevel gears have (i) Hypoid gears have curved teeth.
smooth teeth engagement, which results in quiet
(ii) Hypoid gears are mounted on non- non
operation, even
ven at high speeds. They have better
strength and are thus used for high speed
speed-high parallel and non-intersecting
intersecting shafts.
power transmission. Hypoid bevel gears are mainly used in automobile
differentials. Advantage of hypoid gears is that the
offset of the shaft is so great that the shaft may
continue past each other.
Ques: - What are the different types of mountings of bevel gear? (MAY 15)
The Different types of mountings used in bevel gears pairs are discussed below:
1. Straddle Mounting of pinion and gears:
  In a straddle mounting, two bearings are mounted on either side of the gears.
 A both the pinion and gear are straddle mounted, the deflection is minimum.
 The bevel gear is supported between two taper roller bearings with face to face arrangement or
two angular contact bearings.
 The bevel pinion is usually supported between two deep grove ball bearings, two angular
contact bearings, or sometimes two taper roller bearings with face to face arrangements.
 This arrangement results in highest degree of mounting rigidity. This arrangement is generally
used for industrial and other heavy duty applications.

2. Overhung Mounting of Pinion and Straddle Mounting of Gear:

 In these arrangements shown the gear shaft is mounted between two bearings which are on
either side of the gear. The bearings may be taper roller bearings with face to face arrangements
or angular contact bearings
 The pinion is mounted overhung on the bearings, which may be of single row deep groove type,
taper roller type with back to back arrangements, or angular contact type.
 Because of the overhung mounting, the deflection of the pinion shaft is high. Hence, through
the arraignments is simple, it is used for medium and light loads only.
3. Overhung Mounting of Pinion and Gear:
 In these arrangements, both the pinion and gear are mounted overhung.
 Through this arrangement is very simple, the deflection of both the shafts under the load is
large, and hence is suitable only for light loads.
 Worm Gears

1) Where do you use worm gear drive?

Ans:- The worm gear drives are used to transmit power between two non-intersecting shafts,
which are, in general, worm general, at right angles to each other. The worm gear drive consists
of a worm and a worm wheel. The worm is a threaded screw, while the worm wheel is a toothed
gear. The teeth on the worm wheel envelope the threads on the worm and give line contact
between mating parts.
2) What are the advantages of worm gear drives?
Ans:- The advantages of worm gear drives are as follows:
 The most important characteristic of worm gear drives is their high speed reduction. A
speed reduction as high as 100:1 can be obtained with a single pair of worm gears.
 The worm gear drives are compact with small overall dimensions, compared with
equivalent spur or helical gear drives having same speed reduction.
 The operation is smooth and silent.
 Provision can be made for self-locking operation, where the motion is transmitted only
from the worm to the worm wheel. This is advantageous in applications like cranes and
lifting devices.
3) What are the drawbacks of worm gear drives?
Ans:- The disadvantages of worm gear drives are as follows:
 The efficiency is low compared with other types of gear drives.
 The worm wheel, in general, is made of phosphor bronze, which increases the cost.
 Considerable amount of heat is generated in worm gear drives, which is required to be
dissipated by a lubricating oil to the housing walls and finally to the surroundings.
 The power transmitting capacity is low. Worm gear drives are used for up to 100 kW of
power transmission.
4) Why worm gear is always weaker than the worm?
Ans: -
1. In worm gear drive, due to sliding motion the considerable friction is there. To reduce
this, worm wheel is made up of Phosphor Bronze which has anti-scoring and anti-friction
properties which reduce coefficient of friction.
2. Worm is subjected to bending and torsion hence it is made up of plain carbon steel or
alloy steel material which have high strength and ductility.
In worm gear drive, worm is a threaded screw and worm wheel is a toothed wheel. In this case
the threads of worm is always strong than the teeth of the worm wheel. Also worm wheel is
made up by Phosphor Bronze material and worm is made up of case hardened steel material.
Phosphor Bronze material is weaker than the case hardened steel material. Hence in worm gear
drive the worm wheel is weaker than the worm. Therefore in worm gear drive, the design is
depends on worm wheel.
5) Explain Efficiency of worm and worm gear drive? Discuss factors affecting efficiency of
worm gear pair?
Ans: - The efficiency of the worm gear drive is the ratio of out power to the input power
and given by,
𝑃𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡
𝜂=
𝑃𝑜𝑤𝑒𝑟 𝑖𝑛𝑝𝑢𝑡
But we have,
2𝜋 × 𝑁 × (𝑀 ) 2𝜋 × 𝑁 (𝑃 ) × 𝑑
(𝐾𝑊 ) / = = × 𝑎𝑛𝑑
60 × 10 60 × 10 2
2𝜋 × 𝑁 × (𝑀 ) 2𝜋 × 𝑁 (𝑃 ) × 𝑑
(𝐾𝑊 ) / = = = ×
60 × 10 60 × 10 2
(𝑃 ) × 𝑑 × (𝑁 )
𝜂= … … … … … … … … (𝐼 )
(𝑃 ) × 𝑑 × (𝑁 )
But, we have, 𝑖= ∴ =
𝑑 𝑚𝑍 𝑍 /𝑍 𝑖
= = = = 𝑖 × tan 𝛾
𝑑 𝑚𝑞 𝑞/𝑍 1/ tan 𝛾
[(𝑐𝑜𝑠𝛼 × 𝑐𝑜𝑠𝛾 ) − (𝜇 × 𝑠𝑖𝑛 𝛾 )]
(𝑃 ) = (𝑃 ) = (𝑃 ) ×
[(𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 ) + (𝜇 × 𝑐𝑜𝑠 𝛾 )]
Put in equation (I) we get,
[(𝑐𝑜𝑠𝛼 × 𝑐𝑜𝑠𝛾 ) − (𝜇 × 𝑠𝑖𝑛 𝛾 )]
𝜂 = tan 𝛾 ×
[(𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 ) + (𝜇 × 𝑐𝑜𝑠 𝛾 )]
sin 𝛾 [(𝑐𝑜𝑠𝛼 × 𝑐𝑜𝑠𝛾 ) − (𝜇 × 𝑠𝑖𝑛 𝛾 )]
𝜂= ×
cos 𝛾 [(𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 ) + (𝜇 × 𝑐𝑜𝑠 𝛾 )]
( × ) ( × )
−
𝜂= ( × ) ( × )
+
[(𝒄𝒐𝒔𝜶) − (𝝁 × 𝒕𝒂𝒏 𝜸)]
𝜼=
[(𝒄𝒐𝒔𝜶) + (𝝁 × 𝒄𝒐𝒕 𝜸)]
Factors Affecting Efficiency of Worm Gear Drive: - The efficiency of worm gear drive is low
and varies considerably in the range of 50% to 98%. In general, the efficiency is inversely
proportional to speed ratio, provided the coefficient of friction is constant. It depends on the lead
angle and coefficient of friction between worm and wheel. The efficiency increases rapidly up-to
lead angle 200. After which the increase of efficiency is low. For better efficiency, multi-start
worms are selected.
6) Derive an expression for components of forces acting on worm and worm gear?
Ans: - The three components of the gear tooth force between the worm and the worm
wheel are shown in Figure. Let,
For Worm,
(P1)t = Tangential component (N)
(P1)a = Axial component (N)
(P1)r = Radial component (N)
For Wheel
(P2)t = Tangential component ((N)
(P2)a = Axial component (N)
(P2)r = Radial component (N)
Then, (P2)t = (P1)a
(P2)a = (P1)t
(P2)r = (P1)r (All are acts in opposite directions)

Components of Tooth Force Components of Normal Reaction

The analysis of three components of the resultant tooth force between the meshing teeth
of worm and worm wheel is based on the following assumptions:
1. The worm is the driving element, while the worm wheel is the driven element.
2. The worm has right-handed
handed threads.
3. The worm rotates in anti-clockwise
clockwise directions.

The resultant force acting on the worm consists of two components

components— —components of
normal reaction between the meshing teeth and components of frictional force. The two
components are superimposed to get the resultant components.
Components of Normal Reactions: - The components of the normal reaction P acting
on the worm are shown in Figure. Here, 𝛼 is the normal pressure angle, while 𝛾 is the
lead angle.
Resolving the normal reaction P in the plane ABCD shown in Figure (b),
𝑃 = 𝑃 × 𝑐𝑜𝑠𝛼 … … … … … (1)
𝑃 = 𝑃 × 𝑠𝑖𝑛𝛼 … … … … … (2)
Resolving the component PN in the plane AEBF shown in Figure (c),
𝑃 = 𝑃 𝑐𝑜𝑠𝛾 = 𝑃 × 𝑐𝑜𝑠𝛼 × 𝑐𝑜𝑠𝛾 … … … … … (𝐴)
𝑃 = 𝑃 sin 𝛾 = 𝑃 × 𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 … … … … (𝐵)
𝑎𝑛𝑑 𝑃 = 𝑃 × 𝑠𝑖𝑛𝛼 … … … … … … … … … … ( 𝐶)
Components nts of Frictional Force(𝝁𝑷): -
The frictional force is significant in worm gear drives, because there is sliding motion
between the threads of the worm and the teeth of the worm wheel, as compared with the
rolling motion between the teeth of the pinion and gear in other types of gears.
The resultant frictional force is (𝜇𝑃) where, (𝜇) is coefficient of friction. The direction of
the frictional force will be along the pitch helix and opposite to the direction of rotation,
as shown in Figure. There are two components of the frictional force:
1. Component (𝜇𝑃) × 𝑐𝑜𝑠 𝛾 in the
tangential direction. The direction of
this component is same as that of Pt.
2. Component (𝜇𝑃) × 𝑠𝑖𝑛 𝛾 in the axial
direction. The direction of this
component is opposite to that of Pa.

Superimposing the components of normal

reaction and frictional force, we have,
Components of Frictional Force
(𝑃 ) = (𝑃 × 𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 ) + (𝜇𝑃 × 𝑐𝑜𝑠 𝛾 ) Where, (𝑃 ) is tangential
(𝑃 ) force for worm and find out
𝑃= … … … … … (3) by using following method,
[(𝑐𝑜𝑠𝛼 × 𝑠𝑖𝑛𝛾 ) + (𝜇 × 𝑐𝑜𝑠 𝛾 )]
(𝑃 ) = (𝑃 × 𝑐𝑜𝑠𝛼 × 𝑐𝑜𝑠𝛾 ) − (𝜇𝑃 × 𝑠𝑖𝑛 𝛾 ) Torque transmitted,
[(𝒄𝒐𝒔𝜶 × 𝒄𝒐𝒔𝜸) − (𝝁 × 𝒔𝒊𝒏 𝜸)] 60 × 10 × 𝑘𝑊
(𝑷𝒂 )𝟏 = (𝑷𝒕 )𝟏 × (𝑀 ) =
[(𝒄𝒐𝒔𝜶 × 𝒔𝒊𝒏𝜸) + (𝝁 × 𝒄𝒐𝒔 𝜸)] 2𝜋
𝜋×𝑁
[𝑺𝒊𝒏 𝜶] Then,
(𝑷𝒓 )𝟏 = (𝑷𝒕 )𝟏 × 2 × (𝑀 )
[(𝒄𝒐𝒔𝜶 × 𝒔𝒊𝒏𝜸) + (𝝁 × 𝒄𝒐𝒔 𝜸)] (𝑃 ) =
𝑑
7) Explain the following i) Lead, ii) Diametral quotient, ii
iii)
i) No. of starts of worm, iv) Lead
angle?
Ans: - i) Lead: - The lead (1) of the worm is defined as the distance that a point on the
helical profile will move, when the worm is rotated through one revolution. It is the
thread advance in one turn. For single-start
start threads, the lead is equal to the axial pitch.
For double-start
start threads, the lead is twice the axial pitch and so on. Therefore,
𝒍 = 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒔𝒕𝒂𝒓𝒕𝒔 × 𝒑𝒙 = 𝒁𝟏 × 𝒑𝒙
ii) Diametral quotient: - It is ratio of Pitch circle diameter of worm to module of worm.
𝒅𝟏
The diametral quotient is given by, 𝒒 =
𝒎
where, d1 - pitch circle diameter of the worm 𝒅𝟏 = 𝒎𝒒.
When value of q is larger, P.C.D. of worm is also larger and hence str
strength
ength and rigidity
of worm shaft is higher. When the value of q is larger, lead angle is smaller which
reduces the efficiency of worm gear pair. In practice diameter quotient is taken between 6
to 15. For normal design it is taken as 10
iii) No. of starts of worm: - It is the number of thread helices cut around the cylindrical
body of the worm along the length of the worm. It is denoted by z1 and depends on the
speed ratio.
iv) Lead angle: - The lead angle (𝛾) is defined as the angle between a tangent to the
thread at the pitch diameter and a plane normal to the worm axis. It is find out by using
following equation.
𝒍 𝝅𝒎𝒛𝟏 𝒛𝟏
𝐭𝐚𝐧 𝜸 = = =
𝝅𝒅𝟏 𝝅(𝒒𝒎) 𝒒
8) Write short note on thermal consideration in worm gear?
Ans: - The efficiency of worm gear drive is low and the work done by friction is
converted into heat. When the worm gears operate continuously, considerable amount
of heat is generated.
The rate of heat generated (Hg) is given by,
𝐻 = 1000 (1 − 𝜂 )𝑘𝑊 … … … … (1)
where,
Hg = rate of heat generation (W)
𝜂 = efficiency of worm gears (fraction)
kW = power transmitted by gears (kW)
The heat is dissipated through the lubricating oil to the housing wall and finally to the
surrounding air.
The rate of heat dissipated (Hd ) by the housing walls to the surrounding air is given by,
𝐻 = 𝑘 (𝑡 − 𝑡 ) × 𝐴 … … … (2)
where,
Hd = the rate of heat dissipation (W)
k = overall heat transfer coefficient of housing walls (W/m2 °C)
t = temperature of the lubricating oil (°C)
to = temperature of the surrounding air (°C)
A = effective surface area of housing (m2 ).
Equating equation (1) and (2),
1000 (1 − 𝜂 )𝑘𝑊 = 𝑘 (𝑡 − 𝑡 ) × 𝐴
The above equation is written in the following two ways:
𝑘 (𝑡 − 𝑡 )𝐴 1000(𝑙 − 𝜂 )𝑘𝑊
𝑘𝑊 = 𝑜𝑟 𝑡= 𝑡 +
100(𝑙 − 𝜂) 𝑘𝐴
Above Equations gives the power transmitting capacity based on thermal considerations
or the resultant temperature of the lubricating oil for a given power transmitting capacity.
9) Explain why in design of worm gear, worm gear governs the design. Also explain single
enveloping and double enveloping worm gear with sketch?
Ans: -
 1. In worm gear drive, due to sliding motion the considerable friction is there. To
reduce this, worm wheel is made up of Phosphor Bronze which has anti-scoring and
anti-friction properties which reduce coefficient of friction.
2. Worm is subjected to bending and torsion hence it is made up of plain carbon steel
or alloy steel material which have high strength and ductility.
In worm gear drive, worm is a threaded screw and worm wheel is a toothed wheel. In this
case the threads of worm is always strong than the teeth of the worm wheel. Also worm
wheel is made up by Phosphor Bronze material and worm is made up of case hardened
steel material. Phosphor Bronze material is weaker than the case hardened steel material.
Hence in worm gear drive the worm wheel is weaker than the worm. Therefore in worm
gear drive, the design is depends on worm wheel.
10) Write a short note on thermal consideration in worm gear?
Ans: - The efficiency of worm gear drive is low and the work done by friction is
converted into heat. When the worm gears operate continuously, considerable amount
of heat is generated.
The rate of heat generated (Hg) is given by,
𝐻 = 1000 (1 − 𝜂 )𝑘𝑊 … … … … (1)
where,
Hg = rate of heat generation (W)
𝜂 = efficiency of worm gears (fraction)
kW = power transmitted by gears (kW)
The heat is dissipated through the lubricating oil to the housing wall and finally to the
surrounding air.
The rate of heat dissipated (Hd ) by the housing walls to the surrounding air is given by,
𝐻 = 𝑘 (𝑡 − 𝑡 ) × 𝐴 … … … (2)
where,
Hd = the rate of heat dissipation (W)
k = overall heat transfer coefficient of housing walls (W/m2 °C)
t = temperature of the lubricating oil (°C)
to = temperature of the surrounding air (°C)
A = effective surface area of housing (m2 ).
Equating equation (1) and (2),
1000 (1 − 𝜂 )𝑘𝑊 = 𝑘 (𝑡 − 𝑡 ) × 𝐴
The above equation is written in the following two ways:
𝑘 (𝑡 − 𝑡 )𝐴 1000(𝑙 − 𝜂 )𝑘𝑊
𝑘𝑊 = 𝑜𝑟 𝑡= 𝑡 +
100(𝑙 − 𝜂) 𝑘𝐴
Above Equations gives the power transmitting capacity based on thermal considerations
or the resultant temperature of the lubricating oil for a given power transmitting capacity.
As per AGMA standards, the limiting Input power rating of worm gear drive based on
heat dissipation is given by,
 𝑎 .
𝐾𝑊 / =
34.5 (𝑖 + 5)
Where, a is centre distance and i is speed ratio for worm gear drive.
11) Why worm and worm wheel are made of dissimilar material?
Ans: - 1) In worm gear drive, due to sliding motion the considerable friction is there. To
reduce this, worm wheel is made up of Phosphor Bronze which has anti-scoring and anti-
friction properties which reduce coefficient of friction.
2) Worm is subjected to bending and torsion hence it is made up of plain carbon steel or
alloy steel material which have high strength and ductility.
12) In design of worm gear, why worm gear governs the design?
Ans: - In worm gear drive, worm is a threaded screw and worm wheel is a toothed wheel.
In this case the threads of worm is always strong than the teeth of the worm wheel. Also
worm wheel is made up by Phosphor Bronze material and worm is made up of case
hardened steel material. Phosphor Bronze material is weaker than the case hardened steel
material. Hence in worm gear drive the worm wheel is weaker than the worm. Therefore
in worm gear drive, the design is depends on worm wheel.
13) Explain overhauling and self locking conditions for worm gearing?
Ans: - In general, the worm is the driver and the worm wheel is the driven member and
the reverse motion is not possible. This is called ‘self-locking’ drive, because the worm
wheel cannot drive the worm. The condition for self-locking is as for screw threads, the
criterion for self-locking is the relationship between the coefficient of friction and lead
angle. A worm gear drive is said to be self-locking if the coefficient of friction is greater
than tangent of lead angle, i.e., the friction angle is more than the lead angle. This
approximate condition is rewritten as, μ > tan (γ)
There is another term, ‘reversible’ or ‘overrunning’ or ‘back-driving’ worm gear drive. In
this type of drive, the worm and worm wheel can drive each other. In general, the worm
is the driver and the worm wheel is the driven member. If the driven machinery has large
inertia and if the driving power supply is cut off suddenly, the worm is freely driven by
the worm wheel. This prevents the damage to the drive and source of power. A worm-
gear drive is said to be reversible if the coefficient of friction is less than tangent of lead
angle, i.e., the friction angle is less than the lead angle. This approximate condition is
rewritten as, μ > tan (γ)
14) In a design of worm gear pair why worm gear governs the design?
Ans: -Material for worm and worm wheel: -
1. In worm gear drive, due to sliding motion the considerable friction is there. To
reduce this, worm wheel is made up of Phosphor Bronze which has anti-scoring
and anti-friction properties which reduce coefficient of friction.
2. Worm is subjected to bending and torsion hence it is made up of plain carbon steel
or alloy steel material which have high strength and ductility.
In worm gear drive, worm is a threaded screw and worm wheel is a toothed wheel. In this
case the threads of worm is always strong than the teeth of the worm wheel. Also worm
wheel is made up by Phosphor Bronze material and worm is made up of case hardened
steel material. Phosphor Bronze material is weaker than the case hardened steel material.
Hence in worm gear drive the worm wheel is weaker than the worm. Therefore in worm
gear drive, the design is depends on worm wheel.
 Bevel Gear
A pair of bevel gears, with 20° pressure angle, consists of a 20 teeth pinion meshing with
a 30 teeth gear. The module is 4 mm, while the face width is 20 mm. The material for the
pinion and gear is steel 50C4 (Sut = 750 N/mm2). The gear teeth are lapped and ground
1 (Class-3) and the surface hardness is 400 BHN. The pinion rotates at 500 rpm and
receives 2.5 kW power from the electric motor. The starting torque of the motor is 150%
of the rated torque. Determine the factor of safety against bending failure and against
pitting failure. Take Y=0.33712
A pair of straight bevel gears is mounted on shafts, which are intersecting at right
angles. The number of teeth on the pinion and gear are 21 and 28 respectively. The
pressure angle is 20°. The pinion shaft is connected to an electric motor developing 5 kW
rated power at 1440 rpm. The service factor can be taken as 1.5. The pinion and the gear
2
are made of steel (Sut = 750 N/mm2) and heat-treated to a surface hardness of 380 BHN.
The gears are machined by a manufacturing process, which limits the error between
meshing teeth to 10 μm. The module and face width are 4 mm and 20 mm respectively.
Determine the factor of safety for bending as well as for pitting. Take Y = 0.345
A pair of bevel gears, with 20° pressure angle, consists of a 30 teeth pinion meshing with
a 45 teeth gear. The module is 6 mm, while the face width is 50 mm. The material for the
pinion and gear is steel 50C4 (Sut = 570 N/mm2) and the surface hardness is 350 BHN.
3
The pinion rotates at 500 rpm and receives 16.5 kW power from the electric motor. The
starting torque of the motor is 150% of the rated torque. Determine the factor of safety
against bending failure and against pitting failure. Take 𝑒 = 20 𝑚𝑖𝑐𝑟𝑜𝑛𝑠
A pair of straight bevel gears is mounted on shafts, which are intersecting at right
angles. The number of teeth on the pinion and gear are 20 and 60 respectively. The
pressure angle is 20°. The pinion shaft is connected to an electric motor developing 5 kW
rated power at 1440 rpm. The service factor can be taken as 1.5 and load distribution
factor 1.2. The pinion and the gear are made of steel (Sut = 700 N/mm2) and heat-treated
4 to a surface hardness of 350 BHN. The module and face width are 5 mm and 45 mm
respectively. Determine the factor of safety for bending as well as for pitting. Take
𝐶 = 11400 𝑁/𝑚𝑚 and e = 50 microns. Take
21𝑣 × (𝐶𝑒𝑏 + 𝑃 )
𝑃 =
21𝑣 + (𝐶𝑒𝑏 + 𝑃 )
A pair of bevel gear consists of Zp = 20, Zq = 30, 𝛼 = 20°, kW = 3, Np = 720 rpm, Cs =
5 1.5, m = 4 mm, b= 20 mm. Both gears are made by steel material with BHN = 400,.
Determine FOS for wear rating.
A pair of bevel gear consists of Zp = 28, Zq = 42, 𝛼 = 20°, m = 6 mm, b= 40 mm.
6 Determine PCD of pinion and gear, Cone distance, Pitch angle for pinion and gear, mid-
point radius for pinion and gear.
A pair of bevel gear consists of Zp = 30, Zq = 40, 𝛼 = 20°, m = 6 mm, b= 50 mm. Both
7 gears are made by same material with. 𝑆 = 600𝑀𝑃𝑎, 𝐸 = 114000𝑁/𝑚𝑚 , 𝜎 =
90𝑁/𝑚𝑚 . Calculate wear strength
A pair of bevel gear consists of Zp = 24, Zq = 48, 𝛼 = 20°, Np = 300 rpm, Cs = 1.5, m = 6
mm, b= 50 mm. Both gears are made by steel material with Sut = 220 N/mm2. The teeth
8
are generated teeth and assume velocity factor is in account. Find (i) Beam Strength (ii)
Static load if FOS = 2, (iii) Rated power.
 A pair of bevel gear consists of Zp = 24, Zq = 48, 𝛼 = 20°, Np = 300 rpm, Cs = 1.5, BHN
= 230, m = 6 mm, b= 50 mm. Both gears are made by cast Iron material with S ut = 220
9
N/mm2 and BHN=230. The teeth are generated teeth and assume velocity factor is in
account. Find Rated power at FOS=2.
A pair of bevel gear consists of Zp = 30, Zq = 45, 𝛼 = 20°, Np = 600 rpm, Cs = 1.5, BHN
= 230, m = 6 mm, b= 50 mm. Both gears are made by cast Iron material with S ut = 600
10
N/mm2. The teeth are generated teeth and assume velocity factor is in account. Find
Rated power at FOS=2.
A pair of bevel mounted on shaft with Zp = 24, Zq = 72, 𝛼 = 20°, Np = 300rpm, Cs = 1.5,
FOS = 1.75, m = 6 mm, b =50 mm, = e = 0.0125. Both gears are made by CI
11
material with Sut = 220 N/mm2. The teeth are generated. Calculate Beam strength, rated
power and BHN.
A pair of bevel mounted on shaft with Z p = 24, Zq = 32, kW= 12, 𝛼 = 20°, Np = 1440
rpm, Cs = 1.5, e = 0.0125. Both gears are made by steel material with Sut = 750 N/mm2.
The teeth are generated. Take FOS = 2 and (i) Find Module, assume velocity factor is in
12
account if v = 7.5 m/sec (ii) determine the dynamic load by using the Buckingham’s
equation and find out effective load, (iii) find correct FOS for bending,(iv) Specific BHN
if FOS = 2. Take Y=0.358
A pair of bevel mounted on shaft with Z p = 18, Zq = 45, kW= 25, 𝛼 = 20°, Np = 1500
rpm, Cs = 1.25, e = 27.41 microns. Both gears are made by steel material with Sut = 720
13 N/mm2. Take FOS = 1.75, BHN=420. Assume velocity factor is in account if v = 5 m/sec
find Module. Check the design by using dynamic load is in account. Take Y=0.336 and
𝐶 =

Worm Gear
A pair of worm gear drive is designated as 2/54/10/5. Calculate, i) Centre Distance; ii)
14
Speed reduction; iii) Dimensions of worm and wheel.
A pair of worm gear drive is designated as 1/30/10/8. Calculate, i) Centre Distance; ii)
15
Speed reduction; iii) Dimensions of worm and wheel.
A pair of worm gear drive is designated as 2/52/10/4. The worm transmits 10 kW at 720
16
rpm. Take 𝜇 = 0.04, 𝛼 = 20 Calculate forces acting on worm and wheel.
A pair of worm gear drive is designated as 3/60/10/6. The worm transmits 5 kW at 1440
17
rpm. Take 𝜇 = 0.1, 𝛼 = 20 Calculate forces acting on worm and wheel.
A pair of worm gear drive is designated as 2/60/10/6. The worm transmits 5 kW at 1440
18
rpm. Take 𝜇 = 0.05, 𝛼 = 20 Calculate forces acting on worm and wheel.
A pair of worm gear drive has following data, 𝑍 = 1, 𝑑 = 60 𝑚𝑚, 𝑘𝑊 = 2.2, 𝑁 =
1000 𝑟𝑝𝑚, 𝑁 = 20 𝑟𝑝𝑚, 𝛼 = 14.5 , 𝑃 = 15.7 𝑚𝑚. Worm is above the gear and
rotates in anti-clockwise direction as viewed from right hand side. Find i) Forces acting
19 on worm and wheel; ii) Efficiency of worm gear drive; iii) Power lost in friction; iv)
Designation of worm gear drive; v) whether or not the drive is self locking. Take
.
𝜇=
.

A pair of worm gear drive has following data, 𝑍 = 3, 𝑑 = 90 𝑚𝑚, 𝑘𝑊 = 3, 𝑁 =

20 1440 𝑟𝑝𝑚, 𝑍 = 60, 𝑚 = 4 𝑚𝑚, 𝛼 = 20 , 𝜇 = 0.1. Worm has right hand threads and
worm is above the gear and rotates in clockwise direction as viewed from left hand side.
 Find i) Forces acting on worm and wheel; ii) Efficiency of worm gear drive.
A pair of worm gear drive has following data, 𝑍 = 2, 𝑞 = 10, 𝑘𝑊 = 10, 𝑁 =
720 𝑟𝑝𝑚, 𝑍 = 52, 𝑚 = 4 𝑚𝑚, 𝛼 = 20 , 𝜇 = 0.04. Worm has left hand threads and
21
worm is above the gear and rotates in clockwise direction as viewed from left hand side.
Find i) Forces acting on worm and wheel; ii) Efficiency of worm gear drive
A pair of worm gear drive has following data, 𝑍 = 1, 𝑞 = 10 , 𝑍 = 30, 𝑚 = 8 𝑚𝑚,
22 𝛼 = 20 𝑁 = 1440 𝑟𝑝𝑚 , 𝐴 = 1.5 𝑚 , 𝑘 = 15𝑊/𝑚 𝐶 𝑎𝑛𝑑 ∆𝑡 = 50 𝐶, 𝜇 = 0.024.
Find the rated power on the basis of thermal consideration.
A pair of worm gear drive has following data, 𝑍 = 1, 𝑞 = 10 , 𝑍 = 40, 𝑚 = 4 𝑚𝑚,
23 𝛼 = 20 𝑁 = 1440 𝑟𝑝𝑚 , 𝐴 = 0.25 𝑚 , 𝑘 = 25𝑊/𝑚 𝐶 𝑎𝑛𝑑 ∆𝑡 = 45 𝐶, 𝜇 = 0.035 .
Find the rated power on the basis of thermal consideration.
A pair of worm gear drive is designated as 1/30/10/10. Input speed, 𝑁 = 1200 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by centrifugally
24 Phosphor Bronze material. Find the rated power on the strength basis.
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 28.2 𝑎𝑛𝑑 𝐶𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙𝑙𝑦 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 7.0
𝑎𝑡 𝑁 = 1200 𝑟𝑝𝑚, 𝑋 = 0.25 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 40 𝑟𝑝𝑚, 𝑋 = 0.48
A pair of worm gear drive is designated as 1/40/10/4. Input speed 𝑁 = 1000 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by sand cast
25 Phosphor Bronze material. Find the rated power on the strength basis.
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 28.2 𝑎𝑛𝑑 𝑠𝑎𝑛𝑑 𝑐𝑎𝑠𝑡 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 5.0
𝑎𝑡 𝑁 = 1000 𝑟𝑝𝑚, 𝑋 = 0.265 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 25 𝑟𝑝𝑚, 𝑋 = 0.5
A pair of worm gear drive is designated as 2/40/10/8. Input speed 𝑁 = 1500 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by chilled
26 Phosphor Bronze material. Find the rated power on the strength basis.
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 28.2 𝑎𝑛𝑑 𝑠𝑎𝑛𝑑 𝑐𝑎𝑠𝑡 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 6.4
𝑎𝑡 𝑁 = 1500 𝑟𝑝𝑚, 𝑋 = 0.24 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 75 𝑟𝑝𝑚, 𝑋 = 0.44
A pair of worm gear drive is designated as 1/30/10/10. Input speed 𝑁 = 1200 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by centrifugally
Phosphor Bronze material. Find the rated power on the basis of wear strength.
27
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 4.93 𝑎𝑛𝑑 𝐶𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙𝑙𝑦 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 1.55
𝑎𝑡 𝑁 = 1200 𝑟𝑝𝑚, 𝑋 = 0.112 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 40 𝑟𝑝𝑚, 𝑋 = 0.26
𝐴𝑡 𝑞 = 10 𝑎𝑛𝑑 𝑍 = 1, 𝑌 = 1.143
A pair of worm gear drive is designated as 1/40/10/10. Input speed 𝑁 = 1500 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by Phosphor
Bronze material. Find the rated power on the wear strength basis.
28
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 4.93 𝑎𝑛𝑑 𝐶𝑒𝑛𝑡𝑟𝑖𝑓𝑢𝑔𝑎𝑙𝑙𝑦 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 1.55
𝑎𝑡 𝑁 = 1500 𝑟𝑝𝑚, 𝑋 = 0.1 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 37.5 𝑟𝑝𝑚, 𝑋 = 0.26
𝐴𝑡 𝑞 = 10 𝑎𝑛𝑑 𝑍 = 1, 𝑌 = 1.143
A pair of worm gear drive is designated as 1/40/10/4. Input speed 𝑁 = 1000 𝑟𝑝𝑚.
Worm is made up by case hardened steel while worm wheel is made up by sand cast
Phosphor Bronze material. Find the rated power on the basis of wear rating.
29
𝐹𝑜𝑟 𝑐𝑎𝑠𝑒 ℎ𝑎𝑟𝑑𝑒𝑛𝑒𝑑 𝑠𝑡𝑒𝑒𝑙, 𝑆 = 4.93 𝑎𝑛𝑑 𝑆𝑎𝑛𝑑 𝑐𝑎𝑠𝑡 𝑃ℎ. 𝐵𝑟𝑜𝑛𝑧𝑒, 𝑆 = 1.06
𝑁 = 1000 𝑟𝑝𝑚, 𝑋 = 0.142 𝑎𝑛𝑑 𝑎𝑡 𝑁 = 25 𝑟𝑝𝑚, 𝑋 = 0.35
𝐴𝑡 𝑞 = 10 𝑎𝑛𝑑 𝑍 = 1, 𝑌 = 1.143