Document Type

Article

Publication Date

2025

Department

Engineering

Abstract

This paper presents a new revised Lewis gear bending root stress model for both standard profile and profile-shifted cylindrical gears. The three parameters that are used to extend the root bending stress capacity of standard profile gears to profile-shifted gears are the profile shift radius factor, the profile shift load factor, and the modified Lewis stress factor. These three parameters are functions of the profile shift factor. The new bending capacity model is used to estimate the bending stresses for some standard profile gears with nominal helix angles between 0o to 41.41o and compared with estimates of AGMA model. The stress deviations between the new and AGMA model estimates for the standard profile pinions are in the range of –1 to 10%, indicating a very good match, though slightly conservative. The root bending stress estimates for some profile-shifted gears with nominal helix angles between 0o to 30o were performed using the new gear root bending stress model. Gear root stress values for standard profile and profile-shifted gearsets were compared. The stress deviations between profile-shifted pinions and standard profile pinions are in the range of –5 to -26% with stresses higher for standard profile pinions. These deviations show significant stress reduction with possible increased service life for the profile-shifted gearsets. This is one important reason why addendum modification is attractive.

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