GEARS

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GEARS

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P (Trajectory followed by point “P” is
called Cycloidal Curve)

P (Trajectory followed by point “P” is


called Epi-cycloidal Curve)

Fixed circle
P (Trajectory followed by point “P” is
called Hypo-cycloidal Curve)

Fixed circle

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Why involute curve is widely used?
► In cycloidal gears, for a mating pair, there is only one
theoretical correct centre distance for which this will
transmit motion maintaining a constant angular velocity
ratio.

in case of involute gearing system, the centre distance


can be changed without affecting the angular velocity
ratio.

This advantage of involute system is of prime


importance as most of the modern gears are corrected
ones having changed centre.

@Autogurukul
Why involute curve is widely used?
Also, in case of gearing systems having standard centre
distance, it is not possible to accurately maintain that
distance due to mounting inaccuracies, misalignments
and a number of other diverse factors.

► While the cycloidal tooth profile has double


curvature, an involute tooth has single curvature,
which facilitates ease of manufacturing.

► In involute profile as the path of contact is straight line


and the pressure angle is constant, there is constant
force acting on the axes. In cycloidal gear, the
pressure angle continuously changes. This results in
separating forces of variable magnitude, which in turn
gives rise to unquiet operation

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Disadvantages of involute curve over
cycloidal curve:
► In case of cycloidal gear, minimum number
of teeth can be as low as 6 or 7; but in case
of involute gears, minimum number of teeth
is 17.
► The cycloidal teeth is stronger than the
involute teeth. There is more material at the
root portion of the cycloidal tooth as
compared to an involute tooth.
► Involute teeth has the problem of
interference, but the cycloidal gears do not
have interference and the problem thereof.
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Interference & Undercutting
► The maximum length of the line-of-contact is
limited to the length of the common tangent.
► Any tooth addendum that extends beyond the
tangent points (T and T') is not only useless, but
interferes with the root fillet area of the mating
tooth. This results in the typical undercut tooth.
The undercut not only weakens the tooth with a
wasp-like waist, but also removes some of the
useful involute adjacent to the base circle.
► From the geometry of the limiting length-of-
contact (T-T') it is evident that interference is first
encountered by the addenda of the gear teeth
digging into the mating-pinion tooth flanks.
Continued to next page…….

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Interference & Undercutting

Continued to next page…….


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Interference & Undercutting

Geometry of proper teeth meshing

Tooth correction: One of the


method of avoiding undercut, is tooth
correction or tooth enlargement. This
is achieved by pinion enlargement (or
correction as often termed), wherein
the pinion teeth, still generated with a
standard cutter, are shifted radially
ourward to form a full involute tooth
free of undercut The tooth is enlarged
both radially and circumferentially.
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Interference & Undercutting
► Interference condition becomes more severe as the
number of teeth on the gear increases. The limit is
reached when the gear becomes a rack. This is a
realistic case since the hob is a rack-type cutter. The
result is that standard gears with tooth numbers
below a critical value are automatically undercut in
the generating process. The limiting number of teeth
in a gear
► meshing with a rack is given by the expression:
► Nc = 2/sin²α
► This indicates the minimum number of teeth free of
undercutting decreases with increasing Pressure
angle.
► For 14½º the value of Nc is 32, and for 20° it is 17.
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Interference & Undercutting

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Interference & Undercutting

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Gear Making process
Modern methods of producing gear teeth cover a
wide variety:
► Machining
► Grinding
► Casting
► Molding
► Forming (drawing, extruding, rolling)
► Stamping

Each method offers special characteristics relating


to quality, production quantity, cost, material and
application.
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Machining
Machining constitutes the most important
method of generating gear teeth. It is
suitable for high precision gears in both
small and large quantities.
Various methods of machining is described
below:
► Teeth formation process
► Tooth finishing process

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Teeth formation process

Gear Milling:
Basic Principle: After each tooth is milled,
gear blank is rotated to the next cutting.
► Disadvantage:
(1)Time consuming
(2) Involves heavy stock removal operation
which require high accuracy of indexing
mechanism

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Hob Generation:
This is the most widely used method of cutting gear teeth.
Basic Principle: In this process the work piece rotates in constant
relationship with the cutting tool ie. The gear hob. The rack is in the
form of a worm.
The central section of the hob is identical to that of the worm and
gear. The differences are that the thread of the hob is axially gashed
or fluted in several places so as to form cutting edges, while the sides
and top of these teeth are relieved behind the gash surface to permit
proper cutting action. This arrangement, in eftect, gives an infinitely
long rack so that cutting is both steady and continuous. To generate
the full Width of the gear, the hob slowly traverses the face of the
gear as it rotates.

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Hob Generation:
Thus, the hob has a basic rotary motion and a
unidirectional traverse at right angles.
► Both movements are relatively simple to effect, resulting in a
very accurate process.
► A further advantage of hobbing is that the hob can be swiveled
relative to the blank axis. This permits cutting helical gears of all
angles with the same tooling.
► With regard to accuracy, hobbing is superior to the other cutting
processes. Gears can be directly hobbed to ultra-precision
► tolerances without resorting to any secondary refining
processes.

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Gear shaping:
► It’s a continuous generating process.
► Cutter is a gear with cutting edges. Profile is
generated with number of enveloping cuts
produced by the cutter teeth.
► It is time consuming as time is lost during
return stroke of cutter and half of the total
machining time is spent in metal removal.

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Gear grinding:
► Although grinding is often associated with quantity
fabrication of high quality gears as a secondary refining
operation, it is also a basic process for producing
hardened gears. In addition, many high-precision fine-
pitch gears have their teeth entirely ground from the
blank state.
► There are a number of distinct advantages to ground
gears. These are listed as follows:
1.Achievement of high precision is possible because
the process can remove very little material in the final
pass.
2.Grinding results in a much finer surface finish than
any machining process.
3. Hardened steel alloys can be ground.
4. Residual surface stresses are minimal.
Grinding continued to next page……. @Autogurukul
Tooth finishing process
Lapping:
► Gear finishing process, used after heat treatment.
► It improves surface finish, correct distortions and
improved wear life.
► Lapping also contribute to have proper backlash,
between meshing teeth.

Other tooth finishing operations are shaving,


honning, etc.

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Gear box lubrication
► All gears are delivered from manufacturer without oil.
► Before start up, the gear should be filled with oil
recommended.
► Oil should be filled to oil level indicator.
► The oil level should be checked regularly. The checking must
be made while the drive is stationary.
► Some times, bearings are normally oil lubricated on primary
side and grease lubricated on secondary side.
► First oil change should take place after running-in period.
Drain oil immediately after stop while oil is still worm.
Second oil change should take place after 200 working
hours. Afterwards, oil change is recommended after period
of 2000-4000 working hours depending on working
conditions.

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Gear box lubrication
► The oil in the sump carries out lubrication of the gears and
bearings automatically. Units are fitted with filler, oil level
indicator and breather for easy routine inspection and
maintenance. For low speed application, grease or forced
feed lubrication may be necessary. Maximum heat
dissipation is achieved by means of a radial fan for directing
high velocity air over the cooling ribs of gear case. For
higher capacities, the units are provided with cooling coils in
the lower part of the housing for allowing cool water passing
through a suitable port entry. With pressure lubrication, oil
cooler can be mounted in the oil circuit to achieve more
efficient and effective cooling.

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Gear failure

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Gear failure
Causes for gear failure:
► Surface fatigue:
(a) Case exfoliation
(b) Initial pitting
(c) Progressive pitting
► Scuffing:
(a) Light scuffing
(b) Heavy scuffing
► Abrasive wear:
(a) Foreign matter in the lubricant (scoring)
► Tooth breakage:
(a) Brittle fracture resulting from high shock load
(b) Excessive loading causing fatigue fracture
► Plastic deformation
► Smooth chemical wear
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Case exfoliation

► Ithappens in case of case hardened gears.


Causes:
► Improper case hardening process, causes
uneven case depth. When the gear is
subjected to running conditions, the layer of
hardened case comes out from the soft
core, causing case exfoliation.

Remedies:
► Proper case hardening procedure
► Use of proper lubrication
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Tooth Pitting
► Pitsare formed when material is flaked off the
tooth surface near or below the pitch line due to
heavy contact pressure.
► This is the removal of small bits of metal from the
surface, due to fatigue, thereby leaving small
holes or pits. This is caused by high tooth loads
leading to excessive surface stress, a high local
temperature due to high rubbing speeds, or
inadequate lubrication. Minute cracking of the
surface develops, spreads and ultimately results in
small bits breaking out of the tooth surface.

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Tooth Pitting
Remedies:
• Avoid high load concentration
• Increase surface strength
• Use a higher viscosity oil

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Tooth Scuffing
► These are due to constantly repeated breakage
of the oil film. It happens due to localised
welding between two meshing teeth.
Remedies:
•Use recommended
viscosity oil
•Provide better cooling
by effective spray
lubrication
•Provide good surface
finish

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Tooth Scoring
► This is a heavy scratch pattern extending from
tooth root to tip. It appears as if a heavily-loaded
tooth pair has dragged foreign matter between
sliding teeth. It can be caused by lubricant failure,
incompatible materials and overload.
Remedies:
• Avoid high load
concentration
• Increase
surface
strength
• Use proper lubricant
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Tooth breakage
Tooth breakage occurs due to:
► Repeated overloading
► Impact load during meshing
► Uneven distribution of load due to
misalignment of axes

Remedies:
► Increase tooth bending strength
► Proper design of the gear teeth
► Use large chamfer at the end of the tooth
► Proper assembly of the drive system to avoid
misalignment. @Autogurukul
Plastic deformation

► Sometimes, due to over loading, uneven


stress distribution and misalignment, gear
teeth does not break, but it got distorted,
and permanent plastic deformation takes
place.

Remedies:
► Proper hardness of the gear teeth
► Proper design of the gear teeth
► Proper assembly of the drive system to avoid
misalignment.
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Smooth chemical wear
Cause:
► Presence of mineral impurities in the
lubricant

Remedies:
► Case harden the teeth
► Use proper and pure lubricant
► Good surface finish

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Trouble shooting
Common defects in gearbox:
► Gear heating up
► Gearbox leakage
► Gearbox noise
► Gearbox vibration
► Oil seal whistle

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Gearbox heating up
► High surrounding temperature may cause heating up
► Over loading: If gear box is heating considerably right from
the beginning of its installation, immediate attention
should be paid in the fact whether gearbox was properly
selected, taking into account all the factors under which it
is required to operate.
► Use of wrong lubricant: Depending upon the conditions of
working, proper lubricant must be used.
► Excessive churning: High viscosity of oil or over filling of
the gearbox will produce excessive churning losses
consequently heating up the gearbox.
► Bearing clearance not proper: Improper bearing clearance
may allow the axial floating of shaft and bearing damage.
► Misalignment: Misalignment between the shaft of gearbox
and the prime mover and or the driven load causes non
uniform load on bearing and shafts. Whenever possible,
use common base plate for motor and gearbox or else
proper alignment should be done.
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Gearbox leakage
► Due to over filling, the oil level may rise above the
mark and upto the level of oil seal, and there fore
leakage could start.
► Leakage may very rarely take place through joint
faces between top and bottom half or end caps in
which case tightening of bolts and screws will stop
leakage, if not then a fresh layer of good jointing
compound will have to be applied to the joint
faces.
► Any slight damage to the lips of the oil seals due
to wear or misuse could start leakage, in which
case they need to be replaced.

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Gearbox noise
Causes of noisy gearbox operation:
► Bearing worn out
► Worn out gears
► Foreign particle in the gearbox, may be
mixed with lubricant
► Excessive backlash
► Tooth contact not proper
► Eccentric running of shaft

► Proper action to be taken so that, these errors can be


eliminated.
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Gearbox vibration

► Vibrationis another area for concern. Solid


foundation and perfect alignment is required
for the gearbox. Couplings should be well
balanced to avoid vibration.

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Oil seal whistle

►A dry condition of oil seal lips, which


allowed to continue, will char and ruin oil
seal lips. Smear the oil seal lips with
lubricant and do not let it remain dry even
when stored for a long time.

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THANK YOU

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