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FIGURE 11.9 Basic machine setup of spiral-bevel face-mill generator.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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11.4 GEAR DESIGN CONSIDERATIONS
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11.4.1 Application Requirements Bevel and hypoid gears are suitable for transmitting power between shafts at practically any angle and speed. The load, speed, and special operating conditions must be defined as the first step in designing a gear set for a specific application. A basic load and a suitable factor encompassing protection from intermittent overloads, desired life, and safety are determined from 1. The power rating of the prime mover, its overload potential, and the uniformity of its output torque 2. The normal output loading, peak loads and their duration, and the possibility of stalling or severe loading at infrequent intervals 3. Inertia loads arising from acceleration or deceleration The speed or speeds at which a gear set will operate must be known to determine inertia loads, velocity factor, type of gear required, accuracy requirements, design of mountings, and the type of lubrication. Special operating conditions include 1. 2. 3. 4. 5. 6. 7. 8. Noise-level limitations High ambient temperature Presence of corrosive elements Abnormal dust or abrasive atmosphere Extreme, repetitive shock loading or reversing Operating under variable alignment Gearing exposed to weather Other conditions that may affect the operation of the set
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11.4.2 Selection of Type of Gear Straight-bevel gears are recommended for peripheral speeds up to 1000 feet per minute (ft/min) where maximum smoothness and quietness are not of prime importance. However, ground straight bevels have been successfully used at speeds up to 15 000 ft/min. Plain bearings may be used for radial and axial loads and usually result in a more compact and less expensive design. Since straight-bevel gears are the simplest to calculate, set up, and develop, they are ideal for small lots. Spiral-bevel gears are recommended where peripheral speeds are in excess of 1000 ft/min or 1000 revolutions per minute (r/min). Motion is transmitted more smoothly and quietly than with straight-bevel gears. So spiral-bevel gears are preferred also for some lower-speed applications. Spiral bevels have greater load sharing, resulting from more than one tooth being in contact. Zerol bevel gears have little axial thrust as compared to spiral-bevel gears and can be used in place of straight-bevel gears. The same qualities as defined under straight bevels apply to Zerol bevels. Because Zerol bevel gears are manufactured on the same equipment as spiral-bevel gears, Zerol bevel gears are preferred by some manufacturers. They are more easily ground because of the availability of bevel grinding equipment.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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BEVEL AND HYPOID GEARS 11.11
BEVEL AND HYPOID GEARS
Hypoid gears are recommended where peripheral speeds are in excess of 1000 ft/min and the ultimate in smoothness and quietness is required. They are somewhat stronger than spiral bevels. Hypoids have lengthwise sliding action, which enhances the lapping operation but makes them slightly less efficient than spiral-bevel gears. 11.4.3 Estimated Gear Size Figures 11.10 and 11.11 relate size of bevel and hypoid gears to gear torque, which should be taken at a value corresponding to maximum sustained peak or one-half peak, as outlined below. If the total duration of the peak load exceeds 10 000 000 cycles during the expected life of the gear, use the value of this peak load for estimating gear size. If, however, the total duration of the peak load is less than 10 000 000 cycles, use onehalf the peak load or the value of the highest sustained load, whichever is greater. Given gear torque and the desired gear ratio, the charts give gear pitch diameter. The charts are based on case-hardened steel and should be used as follows: 1. For other materials, multiply the gear pitch diameter by the material factor from Table 11.1. 2. For general industrial gearing, the preliminary gear size is based on surface durability. 3. For straight-bevel gears, multiply the gear pitch diameter by 1.2; for Zerol bevel gears, multiply the gear pitch diameter by 1.3. 4. For high-capacity spiral-bevel and hypoid gears, the preliminary gear size is based on both surface capacity and bending strength. Choose the larger of the gear diameters, based on the durability chart and the strength chart.
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