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Buy off-the-shelf gears from such like as Boston (US)or Deval (UK)

The best book I have used that covers all the real basics in simple language is "GEARS" by H. E. Merrit, an English engineer, published by Pitman. I believe it is currently out of print, but a good library should be able to get a copy. It's treatmnt of bevels is a bit lacking, but they are a...

See http://www.renold.com/Products/Gears/Gears.asp

I assume 1 sun gear is fixed and o/all ratio is large. If this is the case, consider a propriety "harmonic" reducer. Correction of gears to achieve centre distance undermines tooth integrity too much especially if loads are large. I have had experience of just such a problematic drive which we...

I have the BSC Iron & Stell spec's and all the Japanese (JIS) spec's start with a capitalised 'S' followed by further capitalised letters and/or numbers. There is a J55 under the API spec's. Hope that helps,

Corrosion will induce cracks that can significantly reduce endurance limit. Up to 7x has been recorded. Check out: http://www.epi-eng.com/BAS-Fretting.htm http://www.epi-eng.com/RW-ShaftFatigue.htm

Buy a sprocket from Maryland Metrics and modify it to suit your application. http://mdmetric.com/pt1/sprockets/sprockets_bored2.pdf

Is there any components mounted to the shaft in the fracture zone? If there is/are, is there any "coco" staining around the fracture zone. A helical fractute indicates the shaft failed in shear/torsion.

I concur with everybody vis-a-vis the alloy. Power capacity is directly proportional to hardness up to about 660Hv (thereafter it levels off) for contact stress and up to 350Hv for bending. For elevated hardnesses it is a little more complex for bending. Establish the minimum hardness material...

Hello textron22, Definitely Newcastle (BGA lab is there) and I believe Sheffield, both in the UKk

Hi rob768, I believe the effective hardness should relate to the surface hardness. Some medium carbon steels would struggle to get much above 550Hv at the surface, never mind into the case.

Thanks unclesyd, I'm investigating a machine failure where the probable cause is inadequate flame hardening of a plate cam. The surface hardness at 60.5HRc is slightly over spec' (56-60HRc) but the hardness profile passes through the lower limit at only 0.5mm (0.02") deep. The case depth spec'...

I concur with gearguru's comment about EDM. You will though, be surprised to learn that in my experience, broaches are made closer to a radius than the involute. The errors are lost in the fit.

Center Distance? range if nec. dimension over both gears if space is a prob'. Driver/Driven Ratio? Face width (max) Power?

Don't go less than 1.2 CR. A 1.2 minimum CR accounts for geometry errors. The OD has a tolerance, the teeth have tolerences. I've worked in printing engineering for 40+ yrs. The paper will never come thro' the nip at the theoretical thicknes - that is a minimum! So there will be center distance...

DIN 3960 Art 2.7.2 and beyond. Toothed belt pulleys are usually "topped" by the hob; i.e. the major diameter is machined by the hob. Purveyors of such systems do not provide tooth geometry to facilitate such measurements. It is usually sufficient to verify the outeside/major diameter.

Can anybody point me to a referance/website (where I don't have to take out a mortgage to get a hay stack with the pertinent needle)that publishes Hardness Curves for 50CrMo4 Chrome-Moly alloy. SAE/AISI 4150 IS an equiv' alloy and so would suffice for my purposes.

Involute curves take an age to create, gobble up bites, make the drawing unwieldy & can cause prob's in 3D. I always approximate the involute to a radius struck from the base circle tangent to the pitch circle flank intersect. the errors at the tip and root are small. Slines are hobbed and...

Nothing, but both should be expressed as undimensionable coeficients; i.e. refering to unit pitch (1 module or 1 DP) and in the same plane. An unqualified (transverse) add mod coef on a helical will always refer to the normal plane. Maag Gear Book by Maag Gear-Wheel Company, Zurich Switz'...

My Deutsch says "Position Designation added to Overview Drawing" [General Arrangement? Assembly Drawing is "Zusammenbauzeichnung"].