Gears and Gear Trains
Gears and Gear Trains
Gears and Gear Trains
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The materials used for the manufacture of gears depends upon the strength and service
conditions like wear, noise etc.
The gears may be manufactured from metallic or non-metallic materials. The metallic gears
with cut teeth are commercially obtainable in cast iron, steel and bronze.
The non-metallic materials like wood, rawhide, compressed paper and synthetic resins like
nylon are used for gears, especially for reducing noise.
The cast iron is widely used for the manufacture of gears due to its good wearing properties,
excellent machinability and ease of producing complicated shapes by casting method. The cast
iron gears with cut teeth may be employed, where smooth action is not important.
The steel is used for high strength gears and steel may be plain carbon steel or alloy steel. The
steel gears are usually heat treated in order to combine properly the toughness and tooth
hardness.
The phosphor bronze is widely used for worms gears in order to reduce wear of the worms
which will be excessive with cast iron or steel.
1. According to the position of axes of the shafts.
a. Parallel
1.Spur Gear
2.Helical Gear
3.Rack and Pinion
b. Intersecting
Bevel Gear
c. Non-intersecting and Non-parallel
worm and worm gears
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Teeth is parallel to axis of rotation
Transmit power from one shaft to
another parallel shaft
Used in Electric screwdriver, oscillating
sprinkler, windup alarm clock, washing
machine and clothes dryer
Advantages
They offer constant velocity ratio
Spur gears are highly reliable
Spur gears are simplest, hence easiest to design and manufacture
A spur gear is more efficient if you compare it with helical gear of same size
Spur gear teeth are parallel to its axis. Hence, spur gear train does not produce axial thrust. So the gear
shafts can be mounted easily using ball bearings.
They can be used to transmit large amount of power (of the order of 50,000 kW)
Disadvantages
Spur gear are slow-speed gears
Gear teeth experience a large amount of stress
They cannot transfer power between non-parallel shafts
They cannot be used for long distance power transmission.
Spur gears produce a lot of noise when operating at high speeds.
when compared with other types of gears, they are not as strong as them
The teeth on helical gears are cut at an angle to the face of the
gear
This gradual engagement makes helical gears operate much
more smoothly and quietly than spur gears
One interesting thing about helical gears is that if the angles of
the gear teeth are correct, they can be mounted on
perpendicular shafts, adjusting the rotation angle by 90 degrees
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Advantages
The angled teeth engage more gradually than do spur gear teeth causing them to run more
smoothly and quietly
Helical gears are highly durable and are ideal for high load applications.
At any given time their load is distributed over several teeth, resulting in less wear
Can transmit motion and power between either parallel or right angle shafts
Disadvantages
•An obvious disadvantage of the helical gears is a resultant thrust along the axis of the gear,
which needs to be accommodated by appropriate thrust bearings, and a greater degree of sliding
friction between the meshing teeth, often addressed with additives in the lubricant.
Thus we can say that helical gears cause losses due to the unique geometry along the axis of the
helical gear’s shaft.
•Efficiency of helical gear is less because helical gear trains have sliding contacts between the
teeth which in turns produce axial thrust of gear shafts and generate more heat. So, more power
loss and less efficiency
To avoid axial thrust, two
helical gears of opposite hand
can be mounted side by side,
to cancel resulting thrust
forces
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Advantages
Worm gear drives operate silently and smoothly.
They are self-locking.
They occupy less space.
They have good meshing effectiveness.
Disadvantages
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Pitch
circle. It is an imaginary circle which by pure rolling action would give the
same motion as the actual gear.
Pitchcircle diameter. It is the diameter of the pitch circle. The size of the gear is
usually specified by the pitch circle diameter. It is also known as pitch diameter.
Pitch point. It is a common point of contact between two pitch circles.
Pitchsurface. It is the surface of the rolling discs which the meshing gears have
replaced at the pitch circle.
Pressure angle or angle of obliquity. It is the angle between the common normal
to two gear teeth at the point of contact and the common tangent at the pitch point.
It is usually denoted by φ. The standard pressure angles are 14 1/2 ° and 20°.
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Pressure angle
Addendum. It is the radial distance of a tooth from the pitch circle to the top of
the tooth.
Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom
of the tooth.
Addendum circle. It is the circle drawn through the top of the teeth and is
concentric with the pitch circle.
Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also
called root circle.
Note : Root circle diameter =
Pitch circle diameter × cos φ ,
where φ is the pressure angle.
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Circular pitch. It is the distance measured on the
circumference of the pitch circle from a point of one toothto
the corresponding point on the next tooth. It is usually
denoted by Pc ,Mathematically,
A little consideration will show that the two gears will mesh
together correctly, if the two wheels have the same circular
pitch.
Note : If D1 and D2 are the diameters of the two meshing gears
having the teeth T 1 and T 2 respectively, then f or them to
mesh correctly,
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Diametral pitch. It is the ratio of number of teeth to the pitch
circle diameter in millimetres. It is denoted by pd.
M athematically,
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Face of tooth. It is the surface of the gear tooth above the pitch surface.
Flank of tooth. It is the surface of the gear tooth below the pitch surface.
Top land. It is the surface of the top of the tooth.
Face width. It is the width of the gear tooth measured parallel to its axis.
Profile. It is the curve formed by the face and flank of the tooth.
Fillet radius. It is the radius that connects the root circle to the profile of the
tooth.
The common normal at the point
of contact between a pair of teeth
must always pass through the
pitch point .
ⱷ Rb
N
RA
L
ⱷ
G P H
K
ra
M r
Ɵ
rb ⱷ
O1
PATH OF
CONTACT
The length of path of contact is the
length of common normal cut off by
the addendum circles of the wheel
and the pinion.
Thus the length of path of contact is
KL which is the sum of the parts of
the path of contacts KP and PL .
ⱷ Rb
N
RA
L
ⱷ
G P H
K
ra
M r
Ɵ
rb ⱷ
O1
PATH OFCONTACT ⱷ
O2
Rb
radius of the base circle of pinion,
N
ⱷ
G P H
Now from right angled triangle O 2 KN ,
K
ra
M r
Ɵ
rb ⱷ
ⱷ Rb
N
RA
L
ⱷ
G P H
K
ra
M r
Ɵ
rb ⱷ
O1
PATH OFCONTACT ⱷ
O2
Rb
radius of the base circle of pinion,
N
RA
L
radius of the base circle of wheel,
ⱷ
G P H
Similarly from right angled triangle K
ra
O1 ML
M r
Ɵ
rb ⱷ
path of approach ⱷ Rb
N
RA
L
ⱷ
the path of recess G P H
K
ra
M r
Length of the path of contact,
Ɵ
rb ⱷ
O1
ARC OF
CONTACT
• The arc of contact is EPF or GPH.
• Considering the arc of contact GPH,
it is divided into two parts i.e. arc GP
and arc
• PH .
• The arc GP is known as arc of
approach and the arc PH is called arc
of recess .
ARC OF
CONTACT
• the length of the arc of approach (arc GP)
Since the length of the arc of contact GPH is equal to the sum of the length of arc
of approach and arc of recess, therefore, Length of the arc of contact
• The contact ratio or the number of pairs of
teeth in contact is defined as the ratio of the
length of the arc of contact to the circular
pitch.
• Mathematically, Contact ratio or number
of pairs of teeth in contact
The number of teeth on each of the two equal spur gears in mesh are 40. The
teeth have 20° involute profile and the module is 6 mm. If the arc of contact is
1.75 times the circular pitch, find the addendum.
Given : T = t = 40 ; φ= 20° ; m = 6 mm
Adendum=6.12 mm
INTERFERENCE
INTERFERENCE
A little consideration will show, that if the radius of the addendum circle of
pinion is increased to O 1 N , the point of contact L will move from L to N .
When this radius is further increased, the point of contact L will be on the
inside of base circle of wheel and not on the involute profile of tooth on
wheel.
The tip of tooth on the pinion will then undercut the tooth on the wheel at the
root and remove part of the involute profile of tooth on the wheel.
This effect is known as interference , and occurs when the teeth are being
cut. In brief, the phenomenon when the tip of tooth undercuts the root on
its mating gear is known as interference .
O2
ⱷ Rb
N
RA R
L
P ⱷ
G H
K
ra
r
M r
Ɵ
rb ⱷ
O1
INTERFERENCE
The points M and N are called interference points .
Obviously, interference may be avoided if the path of contact does not extend
beyond interference points.
The limiting value of the radius of the addendum circle of the pinion is O 1 N and of
the wheel is O2M.
we conclude that the interference may only be avoided, if the point of contact
between the two teeth is always on the involute profiles of both the teeth.
In other words,
interference may only be prevented, if the addendum circles of
the two mating gears cut the common tangent to the base circles between the
points of tangency .
MINIMUM NUMBER OF TEETH ON THE PINION IN
ORDER TO AVOID INTERFERENCE
O2
ⱷ Rb
N
RA R
L
P ⱷ
G H
K
ra
r
M r
Ɵ
rb ⱷ
O1
O2
t = Number of teeth on the pinion,,
ⱷ Rb
T = Number of teeth on the wheel,
m = Module of the teeth,
N
r = Pitch circle radius of pinion = m.t / 2 R
RA
L
G = Gear ratio = T / t = R / r
φ=Pressure angle or angle of obliquity. P ⱷ
Let AP.m = Addendum of the pinion, where AP is a fraction by G H
which the standard addendum of one module for the pinion
should be multiplied in orderto avoid interference. K
ra
From triangle O 1 NP ,
r
M r
Ɵ
rb ⱷ
O1
This equation gives the minimum number of teeth required on the pinion
in order to avoid interference.
MINIMUM NUMBER OF TEETH ON THE WHEEL IN
ORDER TO AVOID INTERFERENCE
O2
ⱷ Rb
N
RA
L
P ⱷ
G H
K
ra
M r
Ɵ
rb ⱷ
O1
T = Minimum number of teeth required on the wheel in order to avoid
interference, And
A W . m = Addendum of the wheel, where A W is a fraction by which the standard
addendum for the wheel should be multiplied.
from triangle O2MP
MINIMUM NUMBER OF TEETH TO
AVOID INTERFERENCE
On pinion
On wheel
Determine the minimum number of teeth required on a pinion, in
order to avoid interference which is to gear with,
1. a wheel to give a gear ratio of 3 to 1 ; and 2. an equal wheel.
The pressure angle is 20° and a standard addendum of 1 module for
the wheel may be assumed.
Given : G = T / t = 3 ; φ = 20° ; A W = 1 module
t=16
t=13
A pair of involute spur gears with 16° pressure angle and pitch of module
6 m m is in mesh. The number of teeth on pinion is 16 and its rotational
speed is 240 r.p.m . W hen the gear ratio is 1.75, find in order that the
interference is just avoided ; 1. the addenda on pinion and gear wheel ; 2.
the length of path of contact ; and 3. the maximum velocity of sliding of
teeth on either side of the pitch point.
Given : φ=16° ; m = 6 mm ; t = 16 ; N 1 = 240 r.p.m. or ω1=2π × 240/60 = 25.136 rad/s ;
G = T / t = 1.75 or T = G.t = 1.75 × 16 =28
Addendum of pinion=10.76mm
Addendum of wheel=4.56mm
R A = R + Addendum of wheel = 84 + 10.76 = 94.76 mm
rA = r + Addendum of pinion = 48 + 4.56 = 52.56 mm
KP=26.45mm; PL=11.94mm;
KL = KP + PL = 26.45 + 11.94 = 38.39 mm
W2=14.28rad/sec
Sliding velocity during engagement= 1043mm/s
Sliding velocity during disengagement= 471mm/s
Helical gears can be used in a variety of applications since they can be
mounted on either parallel or on 90° non-intersecting shafts.
Ratio of the speed of the driven or follower to the speed of the driver is known as
train value of the train value.
speed ratio and the train value, in a simple train of gears, is independent of the
size and number of intermediate gears.
When there are more than one gear on a shaft, it is called a
compound train of gear .
TB + TE = TC + TD
TE = TC + TD – TB = 30 + 90 – 75 = 45
400 r.p.m. (anticlockwise)
An epicyclic gear consists of three gears A, B and C as shown in
Fig. The gear A has 72 internal teeth and gear C has 32 external
teeth. The gear B meshes with both A and C and is carried on an
arm EF which rotates about the centre of A at 18 r.p.m.. If the gear
A is fixed, determine the speed of gears B and C.
Given : TA = 72 ; TC = 32 ; Speed of arm EF = 18 r.p.m.
58.5 r.p.m 46.8 r.p.m.
Anepicyclic train of gears is arranged as shown in Fig.. How many revolutions
does the arm , to which the pinions B and C are attached , make :
1.when A makes one revolution clockwise and D m a kes half a revolution
anticlockwise , and
2. when A makes one revolution clockwise and D is stationary ?
The number of teeth on the gears A and D are 40 and 90respectively .
Given : T A = 40 ; T D = 90
dA + dB + dC = dD or dA + 2 dB = dD ...( dB = dC)
Since the number of teeth are proportional to
their pitch circle diameters, therefore,
TA + 2 TB= TD or 40 + 2 TB = 90
TB = 25, and TC = 25
1. Speed of arm when A makes 1 revolution clockwise and D makes half revolution anticlockwise 0.04
revolution anticlockwise
2. Speed of arm when A makes 1 revolution clockwise and D is stationary Speed of arm = – y = –0.308
= 0.308 revolution clockwise
In an epicyclic gear train , the internal wheels A and B and compound wheels C
and D rotate independently about axis O. The wheels E and F rotate on pins
fixed to the arm G. E gears with A and C and F gears with B and D. All the
wheels have the same module and the number of teeth are : TC = 28; TD = 26;
TE = TF = 18. 1. Sketch the arrangement ; 2. Find the number of teeth on A and
B ; 3. If the arm G makes 100 r.p.m. clockwise and A is fixed, find the speed of B ;
and 4. If the arm G makes 100 r.p.m. clockwise and wheel A makes 10 r.p.m.
counter clockwise ; find the speed of wheel B.
Given : TC = 28 ; TD = 26 ; TE = TF = 18
1. Sketch the arrangement
The arrangement is shown in Fig. 13.12.
2.Number of teeth on wheels A and B
Let TA = Number of teeth on wheel A, and
TB = Number of teeth on wheel B.
If dA , dB , dC , dD , dE and dF are the pitch circle diameters of wheels A, B, C, D, E
and F respectively, then from the geometry of Fig. 13.12,
dA = dC + 2 dE and dB = dD + 2 dF
Since the number of teeth are proportional to their pitch circle diameters, for the
samemodule, therefore
TA = TC + 2 TE = 28 + 2 × 18 = 64 Ans.
and TB = TD + 2 TF = 26 + 2 × 18 = 62 Ans.
3. Speed of wheel B when arm G makes 100 r.p.m. clockwise and wheel A is fixed 4.2 r.p.m. clockwise
4.Speed of wheel B when arm G makes 100 r.p.m. clockwise and wheel A makes 10 r.p.m. counter clockwise 5.4 r.p.m.
counter clockwise
In an epicyclic gear of the ‘ sun and planet’ type shown in Fig. , the pitch
circle diameter of the internally toothed ring is to be 224 m m and the
module 4 mm. When the ring D is stationary, the spider A, which carries
three planet wheels C of equal size, is to make one revolution in the same
sense as the sunwheel B for every five revolutions of the driving spindle
carrying the sunwheel B. Determine suitable numbers of teeth for all the
wheels.
Given : dD = 224 mm ; m = 4 mm ; NA = NB / 5
TD = dD / m = 224 / 4 = 56 Ans. TC = 21 Ans.
TB = TD / 4 = 56 / 4 = 14 Ans.
Two shafts A and B are co-axial. A gear C (50 teeth) is rigidly mounted
on shaft A. A compound gear D-E gears with C and an internal gear G.
D has 20 teeth and gears with C and E has 35 teeth and gears with an
internal gear G. The gear G is fixed and is concentric with the shaft
axis. The compound gear D-E is mounted on a pin which projects from
an arm keyed to the shaft B. Sketch the arrangement and find the
number of teeth on internal gear G, assuming that all gears have the
same module. If the shaft A rotates at 110 r.p.m. , find the speed of
shaft B.
Speed of shaft B = Speed of arm = + y = 50 r.p.m. anticlockwise
Fig shows a differential gear used in a motor car. The
pinion A on the propeller shaft has 12 teeth and gears with
the crown gear B which has 60 teeth. The shafts P and Q
form the rear axles to which the road wheels are attached.
If the propeller shaft rotates at 1000 r.p.m. and the road
wheel attached to axle Q has a speed of 210 r.p.m. while
taking a turn, find the speed of road wheel attached to
axle P.
Speed of road wheel attached to axle P = Speed of gear C = x + y
= – 10 + 200 = 190 r.p.m.
x = – 563.8 and y = 563.8