Dudley s Handbook of Practical Gear Design and Manufacture Second Edition by Stephen Radzevich ISBN 978-1439866016 1439866016
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Product details:
ISBN 10: 1439866016
ISBN 13: 978-1439866016
Author: Stephen P. Radzevich
A unique, single source reference for all aspects of gears, Dudley’s Handbook of Practical Gear Design and Manufacture, Second Edition provides comprehensive and consistent information on the design and manufacture of gears for the expert and novice alike.The second edition of this industry standard boasts seven new chapters and appendices as well as a wealth of updates throughout. New chapters and expanded topics include: Gear Types and Nomenclature, Gear Tooth Design, Gear Reactions and Mountings, Gear Vibration, The Evolution of the Gear Art, Novikov Gearing and the Inadequacy of the Term, and thoroughly referenced Numerical Data Tables.
Features:
Offers a single-source reference for all aspects of the gear industry
Presents a comprehensive and self-consistent collection of knowledge, practical methods, and numerical tables
Discusses optimal design and manufacture of gears of all known designs for the needs of all industries
Explains concepts in accessible language and with a logical organization, making it simple to use even by beginners in the field
Provides adequate recommendations for gear practitioners in all areas of gear design, production, inspection, and application
Includes practical examples of successful use of tools covered in the Handbook
Logically organized and easily understood, the Handbook requires only a limited knowledge of mathematics for adequate application to almost any situation or question. Whether you are a high-volume gear manufacturer or a relatively small factory, the Handbook and some basic common sense can direct the sophisticated design of any type of gear, from the selection of appropriate material, production of gear blanks, cutting gear teeth, advanced methods of heat treatment, and gear inspection. No other sources of information are necessary for the gear designer or manufacturer once they have the Handbook.
Table of contents:
1 Gear Design Trends
1.1 Small, Low-Cost Gears for Toys, Gadgets, and Mechanisms.
1.2 Appliance Gears.
1.3 Machine Tools.
1.4 Control Gears.
1.5 Vehicle Gears
1.6 Transportation Gears.
1.7 Marine Gears
1.8 Aerospace Gears.
1.9 Industrial Gearing
1.10 Gears in the Oil and Gas Industry
1.11 Mill Gears.
1.12 External Spur Gears.
1.13 External Helical Gears..
1.14 Internal Gears
1.15 Straight Bevel Gears…
1.16 Zerol Bevel Gears
1.17 Spiral Bevel Gears
1.18 Hypoid Gears..
1.19 Face Gears
1.20 Crossed-Helical Gears (Nonenveloping Worm Gears).
1.21 Single-Enveloping Worm Gears..
1.22 Double-Enveloping Worm Gears.
1.23 Spiroid Gears.
2 Gear Types and Nomenclature
2.1 Types of Gears
2.1.1 Classifications
2.1.2 Parallel Axis Gears
2.1.2.1 Spur Gears.
Helical Gears.
2.1.2.3 Internal Gears
2.1.3 Nonparallel, Coplanar Gears (Intersecting Axes).
2.1.3.1 Bevel Gears
2.1.3.2 Face Gears (On-Center).
2.1.3.3 Conical Involute Gearing
2.1.4 Nonparallel, Noncoplanar Gears (Nonintersecting Axes).
2.1.4.1 Crossed-Axis Helical Gears
2.1.4.2 Cylindrical Worm Gearing
2.1.4.3 Single-Enveloping Worm Gearing.
2.1.4.4 Double-Enveloping Worm Gearing.
2.1.4.5 Hypoid Gears..
2.1.4.6 Spiroid and Helicon Gearing.
2.1.4.7 Face Gears (Off-Center)
2.1.5 Special Gear Types.
2.1.5.1 Square or Rectangular Gears.
2.1.5.2 Triangular Gears
2.1.5.3 Elliptical Gears
2.1.5.4 Scroll Gears
2.1.5.5 Multiple-Sector Gears.
2.2 Nomenclature of Gears…
2.2.1 Spur Gear Nomenclature and Basic Formulas
Helical Gear Nomenclature and Basic Formulas.
2.2.3 Internal Gear Nomenclature and Formulas
2.2.4 Crossed Helical Gear Nomenclature and Formulas.
2.2.5 Bevel Gear Nomenclature and Formulas
2.2.5.1 Straight.
2.2.5.2 Spiral
2.2.5.3 Zero
2.2.6 Worm Gear Nomenclature and Formulas.
2.2.6.1 Cylindrical Worm Gears
2.2.6.2 Double-Enveloping Worm Gears.
2.2.7 Face Gears
2.2.8 Spiroid Gear Nomenclature and Formulas..
2.2.9 Beveloid Gears.
3 Gear Tooth Design
3.1 Basic Requirements for Gear Tooth Design
3.1.1 Definition of Gear Tooth Elements.
3.1.2 Basic Considerations for Gear Tooth Design
3.1.2.1 Continuity of Action
3.1.2.2 Conjugate Action
3.1.2.3 Pitch Diameter
3.1.2.4 Zones in Which Involute Gear Teeth Exist.
3.1.2.5 Pointed Teeth
3.1.2.6 Undercut.
3.1.3 Long-and Short-Addendum Gear Design
3.1.3.1 Addendum Modification for Gears Having a Few Teeth.
3.1.3.2 Speed-Increasing Drives
3.1.3.3 Power Drives (Optimal Design).
3.1.3.4 Low-Friction Gearing
3.1.4 Special Design Considerations
3.1.4.1 Interchangeability
3.1.4.2 Tooth Thickness..
3.1.4.3 Tooth Profile Modifications
3.1.4.4 Transverse of Profile Modification.
3.1.4.5 Allowances for Errors of Gear Manufacture.
3.1.4.6 Allowances for Deflection under Load
3.1.4.7 Axial Modifications..
3.1.4.8 Root Fillets.
3.1.4.9 Effective Outside Diameter.
3.1.4.10 Width of Tip of Tooth.
3.1.4.11 Pointed Tooth Diameter
3.1.4.12 Purpose of Backlash..
3.1.4.13 Backlash: Recommended Values.
3.2 Standard Systems of Gear Tooth Proportions
3.2.1 Standard Systems for Spur Gears…
3.2.1.1 Limitations in Use of Standard Tables
3.2.1.2 Standard Tooth Forms That Have Become Obsolete
3.2.1.3 Brown and Sharp System…
3.2.1.4 AGMA 14.5° Composite System
3.2.1.5 Fellows 20° Stub Tooth System..
3.2.1.6 AGMA 14.5° Full-Depth System..
3.2.1.7 Cycloidal Tooth Profiles
3.2.1.8 Clockwork and Timer Tooth Profiles
3.2.1.9 Specific Spur Gear Calculation Procedure
3.2.1.10 Explanation and Discussion of Items in Table 3.5.
3.2.2 System for Helical Gears.
3.2.2.1 Selection of Tooth Form.
3.2.2.2 Selection of Helix Angle.
3.2.2.3 Face Width
3.2.2.4 Specific Calculation Procedure for Helical Gears
3.2.3 System for Internal Gears
3.2.3.1 Special Calculations
3.2.3.2 Specific Calculation Procedure for Internal Gears.
3.2.4 Standard Systems for Bevel Gears.
3.2.4.1 Discussion of 20° Straight Bevel Gear System
3.2.4.2 Discussion of Spiral Bevel Gear System..
3.2.4.3 Discussion of the Zerol Bevel Gear System.
3.2.4.4 Special Tooth Forms….
3.2.4.5 Limitations in 20° Straight Bevel Gear System.
3.2.4.6 Limitations in Spiral Bevel Gear System
3.2.4.7 Limitations in Zerol Bevel Gear System
3.2.4.8 General Comments
3.2.5 Standard Systems for Worm Gears
3.2.5.1 General Practice.
3.2.5.2 Basic Tooth Forms for Worm Gearing.
3.2.5.3 Specific Calculations for Worm Gears
3.2.6 Standard System for Face Gears.
3.2.6.1 Pinion Design
3.2.6.2 Face Gear Design.
System for Spiroid and Helicon Gears.
3.2.7.1 Spiroid Gearing
3.2.7.2 Helicon Gearing
3.2.7.3 Detailed Calculations of Spiroid and Helicon Tooth Data…..
3.3 General Equations Relating to Center Distance
3.3.1 Center Distance Equations
3.3.2 Standard Center Distance.
3.3.3 Standard Pitch Diameters.
3.3.4 Operating Pitch Diameters.
3.3.5 Operating Pressure Angle.
3.3.6 Operating Center Distance.
3.3.7 Center Distance for Gears Operating on Nonparallel Nonintersecting Shafts
3.3.8 Center Distance for Worm Gearing
3.3.9 Reasons for Nonstandard Center Distances
3.3.10 Nonstandard Center Distances.
3.4 Elements of Center Distance.
3.4.1 Effects of Tolerances on Center Distance
3.4.2 Machine Elements that Require Consideration in Critical Center Distance Applications
3.4.3 Control of Backlash
3.4.4 Effects of Temperature on Center Distance
3.4.5 Mounting Distance.
4 Preliminary Design Considerations
4.1 Stress Formulas: Calculation.
4.1.1 Calculated Stresses
4.1.2 Gear Design Limits
4.1.3 Gear Strength Calculations
4.1.3.1 Worst Load
4.1.3.2 Stress Concentration
4.1.3.3 Load Distribution
4.1.3.4 Dynamic Load
4.1.3.5 Finite Element
4.1.4 Gear Surface Durability Calculations.
4.1.4.1 Hertz Derivations.
4.1.4.2 K-Factor Derivations
4.1.4.3 Worst-Load Position.
4.1.4.4 Endurance Limit…
4.1.4.5 Lubrication Regimens.
4.1.5 Gear Scoring.
4.1.5.1 Hot and Cold Scoring
4.1.5.2 PVT Formula
4.1.5.3 Flash Temperature..
4.1.5.4 Scoring Criterion.
4.1.6 Thermal Limits.
4.1.6.1 Thermal Limits at Regular Speed
4.1.6.2 Thermal Limits at High Speed
4.2 Stress Formulas: Special Considerations.
4.2.1 Gear Specifications
4.2.2 Size of Spur and Helical Gears by Q-Factor Method
4.2.2.1 Face-Width Considerations
4.2.2.2 Weight from Volume…
4.2.3 Indexes of Tooth Loading.
4.2.4 Estimating Spur and Helical Gear Size by K-Factor.
4.2.5 Estimating Bevel Gear Size
4.2.6 Estimating Worm Gear Size
4.2.7 Estimating Spiroid Gear Size
4.3 Data Needed for Gear Drawings
4.3.1 Gear Dimensional Data..
4.3.2 Gear Tooth Tolerances
4.3.3 Gear Material and Heat Treatment Data
4.3.4 Enclosed Gear Unit Requirements
5 Design Formulas
5.1 Calculation of Gear Tooth Data
5.1.1 Number of Pinion Teeth
5.1.2 Hunting Teeth
5.1.3 Spur Gear Tooth Proportions.
5.1.4 Root Fillet Radii of Curvature.
5.1.5 Long-Addendum Pinions
5.1.6 Tooth Thickness
5.1.6.1 Backlash
5.1.6.2 Tolerances and Tooth Thickness
5.1.7 Chordal Dimensions
5.1.8 Degrees Roll and Limit Diameter..
5.1.9 Form Diameter and Contact Ratio
5.1.9.1 Form Diameter.
5.1.9.2 Contact Ratio…
5.1.10 Spur Gear Dimension Sheet.
5.1.11 Internal Gear Dimension Sheet
5.1.12 Helical Gear Tooth Proportions.
5.1.13 Helical Gear Dimension Sheet
5.1.14 Bevel Gear Tooth Proportions.
5.1.15 Straight Bevel Gear Dimension Sheet
5.1.16 Spiral Bevel Gear Dimension Sheet..
5.1.17 Zerol Bevel Gear Dimension Sheet
5.1.18 Hypoid Gear Calculations.
5.1.19 Face Gear Calculations.
5.1.20 Crossed-Helical Gear Proportions
5.1.21 Single-Enveloping Worm Gear Proportions.
5.1.22 Single-Enveloping Worm Gears
5.1.23 Double-Enveloping Worm Gears.
5.2 Gear Rating Practice
5.2.1 General Considerations in Rating Calculations
5.2.1.1 Calculation Procedure
5.2.1.2 Grades of Material Quality
5.2.1.3 Reliability of Gears…
5.2.2 General Formulas for Tooth Bending Strength and Tooth Surface
Durability
5.2.2.1 Strength Formula
5.2.2.2 Durability Formula
5.2.2.3 Rating Curves of Stress versus Cycles
5.2.2.4 Rating Bevel Gears.
5.2.3 Geometry Factors for Strength
5.2.3.1 Lack of Load Sharing.
5.2.3.2 Helical Gears with Narrow Face Width
5.2.3.3 Geometry Factors for Strength for Some Standard Designs.
5.2.4 Overall De-Rating Factor for Strength.
5.2.4.1 Application Factor K
5.2.4.2 Load Distribution Factor Km
5.2.4.3 Effect of Helix Error and Shaft Misalignment.
5.2.4.4 Aspect Ratio Effects
5.2.4.5 Load Distribution Factor Km for Bevel Gears
5.2.4.6 Size Factor K
5.2.4.7 Dynamic Load Factors K, and C,
5.2.5 Geometry Factors for Durability
5.2.6 Overall De-Rating Factor for Surface Durability
5.2.6.1 Size Factor C
5.2.6.2 Complementary Considerations
5.2.7 Load Rating of Worm Gearing
5.2.7.1 Crossed-Helical Gear Durability
5.2.7.2 Cylindrical Worm Gear Durability.
5.2.7.3 Double-Enveloping Worm Gear Durability
5.2.7.4 Comparison of Double-Enveloping and Cylindrical Worm Gear Rating Procedures
5.2.8 Design Formulas for Scoring
5.2.8.1 Hot Scoring.
5.2.8.2 Cold Scoring.
5.2.8.3 Design Practice to Handle Scoring
5.2.9 Trade Standards for Rating Gears.
5.2.10 Vehicle Gear Rating Practice.
5.2.11 Marine Gear Rating Practice
5.2.12 Oil and Gas Industry Gear Rating
5.2.13 Aerospace Gear Rating Practice.
6 Gear Materials.
6.1 Steels for Gears.
6.1.1 Mechanical Properties
6.1.2 Heat-Treating Techniques.
6.1.3 Heat-Treating Data.
6.1.4 Hardness Tests
6.2 Localized Hardening of Gear Teeth.
6.2.1 Carburizing.
6.2.2 Nitriding.
6.2.2.1 Features of Nitriding Process.
6.2.2.2 Nitride Case Depth
6.2.3 Induction Hardening of Steel.
6.2.3.1 Induction Hardening by Scanning
6.2.3.2 Load-Carrying Capacity of Induction-Hardened Gear Teeth……
6.2.4 Flame Hardening of Steel.
6.2.5 Combined Heat Treatments
6.2.6 Metallurgical Quality of Steel Gears…
6.2.6.1 Quality Items for Carburized Steel Gears
6.2.6.2 Quality Items for Nitrided Gears.
6.2.6.3 Procedure to Get Grade 2 Quality
6.3 Cast Irons for Gears
6.3.1 Gray Cast Iron
6.3.2 Ductile Iron…
6.3.3 Sintered Iron
6.4 Nonferrous Gear Metals
6.4.1 Kinds of Bronze..
6.4.2 Standard Gear Bronzes
6.5 Nonmetallic Gears.
6.5.1 Thermosetting Laminates
6.5.2 Nylon Gears.
7 Gear-Manufacturing Methods
7.1 Gear Tooth Cutting.
7.1.1 Gear Hobbing.
7.1.2 Shaping-Pinion Cutter.
7.1.3 Shaping-Rack Cutter.
7.1.4 Cutting Bevel Gears.
7.1.5 Gear Milling
7.1.6 Broaching Gears.
7.1.7 Punching Gears.
7.1.8 G-TRAC Generating
7.2 Gear Grinding
7.2.1 Form Grinding
7.2.1.1 Ceramic Form Grinding
7.2.1.2 Borazon Form Grinding
7.2.2 Generating Grinding-Disk Wheel
7.2.3 Generating Grinding-Bevel Gears
7.2.4 Generating Grinding-Threaded Wheel..
7.2.5 Thread Grinding.
7.3 Gear Shaving, Rolling, and Honing.
7.3.1 Rotary Shaving.
7.3.2 Rack Shaving.
7.3.3 Gear Rolling.
7.3.4 Gear Honing
7.4 Gear Measurement…
7.4.1 Gear Accuracy Limits.
7.4.2 Machines to Measure Gears.
7.5 Gear Casting and Forming.
7.5.1 Cast and Molded Gears.
7.5.2 Sintered Gears
7.5.3 Cold-Drawn Gears and Rolled Worm Threads.
8 Design of Tools to Make Gear Teeth
8.1 Shaper Cutters
8.2 Gear Hobs.
8.3 Spur Gear-Milling Cutters
8.4 Worm-Milling Cutters and Grinding Wheels
8.5 Gear-Shaving Cutters
8.6 Punching Tools.
8.7 Sintering Tools.
9 Kinds and Causes of Gear Failures
9.1 Analysis of Gear-System Problems
9.1.1 Determining the Problem.
9.1.2 Possible Causes of Gear-System Failures
9.1.3 Incompatibility in Gear Systems
9.1.4 Investigation of Gear Systems.
9.2 Analysis of Tooth Failures and Gear-Bearing Failures
9.2.1 Nomenclature of Gear Failure
9.2.2 Tooth Breakage.
9.2.3 Pitting of Gear Teeth
9.2.4 Scoring Failures.
9.2.5 Wear Failures.
9.2.6 Gearbox Bearings.
9.2.7 Rolling-Element Bearings.
9.2.8 Sliding-Element Bearings
9.3 Some Causes of Gear Failure Other than Excess Transmission Load.
9.3.1 Overload Gear Failures
9.3.2 Gear-Casing Problems
9.3.3 Lubrication Failures.
9.3.4 Thermal Problems in Fast-Running Gears..
10 Special Design Problems
10.1 Center Distance Problems…
10.2 Profile Modification Problems..
10.3 Load Rating Problem….
11 Gear Reactions and Mountings
11.1 Mechanics of Gear Reactions
11.1.1 Summation of Forces and Moments
11.1.2 Application to Gearing.
11.2 Basic Gear Reactions, Bearing Loads, and Mounting Types
11.2.1 Main Source of Load
11.2.2 Gear Reactions to Bearing
11.2.3 Directions of Loads..
11.2.4 Additional Considerations
11.2.5 Types of Mountings.
11.2.6 Efficiencies
11.3 Basic Mounting Arrangements and Recommendations.
11.3.1 Bearing and Shaft Alignment.
11.3.2 Bearings.
11.3.3 Mounting Gears to the Shaft.
11.3.4 Housing.
11.3.5 Inspection Hole
11.3.6 Break-In
11.4 Bearing Load Calculations for Spur Gears.
11.4.1 Spur Gears
11.4.2 Helical Gears
11.4.3 Gears in Trains
11.4.4 Idlers
11.4.5 Intermediate Gears
11.4.6 Planetary Gears.
11.4.6.1 One Planet
11.4.6.2 Several Planets
11.5 Bearing-Load Calculations for Helicals.
11.5.1 Single Helical Gears..
11.5.2 Double Helical Gears.
11.5.3 Skewed- or Crossed-Helical Gears.
11.6 Mounting Practice for Bevel and Hypoid Gears
11.6.1 Analysis of Forces.
11.6.2 Rigid Mountings.
11.6.3 Maximum Displacements.
11.6.4 Rolling-Element Bearings.
11.6.5 Straddle Mounting.
11.6.6 Overhung Mounting
11.6.7 Gear Blank Design
11.6.8 Gear and Pinion Adjustments..
11.6.9 Assembly Procedure…
11.7 Calculation of Bevel and Hypoid Bearing Loads.
11.7.1 Hand of Spiral
11.7.2 Spiral Angle
11.7.3 Tangential Load.
11.7.4 Axial Thrust.
11.7.5 Radial Load
11.7.6 Required Data for Bearing Load Calculations
11.8 Bearing Load Calculations for Worms
11.8.1 Calculation of Forces in Worm Gears
11.8.2 Mounting Tolerances.
11.8.3 Worm Gear Blank Considerations.
11.8.4 Run-In of Worm Gears
11.9 Bearing Load Calculations for Spiroid Gearing.
11.10 Bearing Load Calculations for Other Gear Types.
11.11 Design of the Body of the Gear.
12 Gear Vibration
12.1 Fundamentals of Vibration
12.2 Measurement of Vibration
12.2.1 Examples of Sensing Devices
12.2.2 Practical Problems in Vibration Measurement.
12.3 Some Examples of Vibration in Geared Units
12.4 Approximate Vibration Limits.
12.4.1 Velocity Limits……..
12.4.2 Acceleration Limits
12.4.3 Proximity Probes
12.4.4 Displacement Limits.
12.4.5 General Vibration Tendencies
12.4.6 Trade Standard
12.5 Control of Vibration in Manufacturing Gears and in the Field.
12.5.1 Testing of Gear Units at the Gear Factory.
12.5.2 Tests of Assembled Power Package.
12.5.3 Vibration Tests in the Field.
12.6 Vibration Analysis Technique…
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