KTM Unit-7

Contents
7.1 Introduction ....................................................................................................................................... 7.2

7.2 Terms Used in Gears......................................................................................................................... 7.7
7.3 Length of Path of Contact And Length of Arc of Contact ............................................................ 7.13
7.4 Interference in Involute Gears ........................................................................................................ 7.15
7.5 Comparison of Cycloidal and Involute tooth forms ...................................................................... 7.21
7.6 Helical and Spiral Gears .................................................................................................................. 7.21
7.7 Introduction to Gear Trains and Its Classification ........................................................................ 7.24
7.8 Problems .......................................................................................................................................... 7.30
7.1 Introduction
If power transmitted between two shafts is small, motion between them may be obtained by using two
plain cylinders or discs 1 and 2.
If there is no slip of one surface relative to the other, a definite motion of 1 can be transmitted to 2 and
vice-versa. Such wheels are termed as “friction wheels”. However, as the power transmitted increases, slip
occurs between the discs and the motion no longer remains definite.
Assuming no slipping of the two surfaces, the following kinematic relationship exists for their linear
velocity:
 To transmit a definite motion of one disc to the other or to prevent slip between the surfaces,
projection and recesses on the two discs can be made which can mesh with each other. This leads
to the formation of teeth on the discs and the motion between the surfaces changes from rolling
to sliding. The discs with the teeth are known as gears or gear wheels.
 It is to be noted that if the disc 1 rotates in the clockwise direction, 2 rotates in the counter-
clockwise direction and vice-versa.
Fig.7.1 – Friction Wheels
7.1.1 Advantages of gear Drive

1. It transmits an exact velocity ratio.
2. It may be used to transmit large power.
3. It has high efficiency.
4. It has a reliable service.
5. It has a compact layout.
7.1.2 Disadvantages of gear Drive

1. The manufacture of gears required special tools and equipment.
2. The error in cutting teeth may cause vibrations and noise during operation.
3. They are costly.
Dr. A. J. Makadia, Department of Mechanical Engineering

7.2 Kinematics and Theory of Machines (3131906) |
Unit-7 Gears and Gear Trains
7.1.3 Classification of Gears
7.1.3.1 According to the position of axes of the shafts

a) Parallel shaft
 Spur gear
The two parallel and co-planar shafts connected by the gears are called spur gears. These gears have
teeth parallel to the axis of the wheel.
They have straight teeth parallel to the axes and thus are not subjected to axial thrust due to tooth
load.
At the time of engagement of the two gears, the contact extends across the entire width on a line
parallel to the axis of rotation. This results in the sudden application of the load, high impact stresses
and excessive noise at high speeds.
If the gears have external teeth on the outer surface of the cylinders, the shaft rotates in the opposite
direction.
In internal spur gear, teeth are formed on the inner surface of an annulus ring. An internal gear can
mesh with an external pinion (smaller gear) only and the two shafts rotate in the same direction.
Fig.7.2 – Spur Gear
 Spur rack and pinion
Spur rack is a special case of a spur gear where it is made of infinite diameter so that the pitch surface
is plane.
The spur rack and pinion combination converts rotary motion into translator motion, or vice-versa.
It is used in a lathe in which the rack transmits motion to the saddle.
Fig.7.3 – Rack and Pinion

Kinematics and Theory of Machines (3131906) | 7.3
 Helical Spur Gears
In helical gears, the teeth are curved, each being helical in shape. Two mating gears have the same
helix angle but have teeth of opposite hands.
At the beginning of the engagement, contact occurs only at the point of the leading edge of the curved
teeth. As the gears rotate, the contact extends along a diagonal line across the teeth. Thus, the load
application is gradual which results in low impact stresses and reduction in noise. Therefore, the
helical gear can be used at higher velocities than the spur gears and have a greater load-carrying
capacity.
Helical gears have the disadvantage of having end thrust as there is a force component along the gear
axis. The bearing and assemblies mounting the helical gears must be able to withstand thrust loads.
Double helical: A double-helical gear is equivalent to a pair of helical gears secured together, one
having a right-hand helix and another left-hand helix.
The teeth of two rows are separated by groove used for tool run out.
Axial thrust which occurs in the case of single-helical gears is eliminated in double-helical gears.
This is because the axial thrusts of the two rows of teeth cancel each other out. These can be run at
highs speeds with less noise and vibrations.
Fig.7.4 – Helical gear
 Herringbone gear
If the left and the right inclinations of a double-helical gear meet at a common apex and there is no
groove in between, the gear is known as Herringbone gear.
Fig.7.5 – Herringbone gear

b) Intersecting Shafts
The two non-parallel or intersecting, but coplanar shafts connected by gears are called bevel gears
When teeth formed on the cones are straight, the gears are known as bevel gears when inclined, they
are known as spiral or helical bevel.
 Straight Bevel Gears
The teeth are straight, radial to the point of intersection of the shaft axes and vary in cross-section
throughout their length.
Usually, they are used to connect shafts at right angles which run at low speeds
Gears of the same size and connecting two shafts at right angles to each other are known as “Mitre”
gears.
Fig.7.6 - Straight Bevel Gears
 Spiral Bevel Gears
When the teeth of a bevel gear are inclined at an angle to the face of the bevel, they are known as spiral
bevels or helical bevels.
They are smoother in action and quieter than straight tooth bevels as there are gradual load
applications and low impact stresses. Of course, there exists an axial thrust calling for stronger
bearings and supporting assemblies.
These are used for the drive to the differential of an automobile.
Fig.7.7 – Spiral Bevel Gears

 Zero Bevel Gears
Spiral bevel gears with curved teeth but with a zero degree spiral angle are known as zero bevel gears.
Their tooth action and the end thrust are the same as that of straight bevel gears and, therefore, can
be used in the same mountings.
However, they are quieter in action than the straight bevel type as the teeth are curved.
Fig.7.8 – Zero Bevel Gear

c) Non-intersecting and non-parallel shaft (Skew shaft)
The two non-intersecting and non-parallel i.e. non-coplanar shaft connected by gears are called skew
bevel gears or spiral gears and the arrangement is known as skew bevel gearing or spiral gearing.
In these gears teeth have point contact.
These gears are suitable for transmitting small power.
A worm gear is a special case of a spiral gear in which the larger wheel, usually, has a hollow shape
such that a portion of the pitch diameter of the other gear is enveloped on it.
Fig.7.9 - Non-intersecting and non-parallel shaft

7.1.3.2 According to the peripheral velocity of the gears
a) Low velocity V < 3 m/sec
(b) Medium velocity 3 < V < 15 m/sec
(c) High velocity V > 15 m/sec
7.1.3.3 According to the position of teeth on the gear surface

(a) Straight,
(b) Inclined, and
(c) Curved
7.2 Terms Used in Gears

1. Pitch circle. It is an imaginary circle which by the pure rolling action, would give the same motion as the
actual gear.
2. Pitch circle 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.
3. Pitch point. It is a common point of contact between two pitch circles.
4. Pitch surface. It is the surface of the rolling discs which the meshing gears have replaced at the pitch
circle.
Fig.7.10 - Terms used in gears
5. 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.
For more power transmission lesser pressure on the bearing and pressure angle must be kept small.
It is usually denoted by ø.
1
The standard pressure angles are 20° and 25°.Gears with 14 ° pressure angle has become obsolete.
2

6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth.
 Standard value = 1 module
7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
 Standard value = 1.157 module
8. Addendum circle. It is the circle drawn through the top of the teeth and is concentric with the pitch
circle.
9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also called the root circle.
10. Clearance. It is the radial difference between the addendum and the Dedendum of a tooth.
Addendum circle diameter  d  2m
Dedendum circle diameter  d  2  1.157m
Clearance  1.157m  m  0.157m

11. Full-depth of Teeth It is the total radial depth of the tooth space.
Full depth= Addendum + Dedendum
12. Working Depth of Teeth The maximum depth to which a tooth penetrates into the tooth space of the
mating gear is the working depth of teeth.
 Working depth = Sum of addendums of the two gears.
13. Working depth. It is the radial distance from the addendum circle to the clearance circle.
It is equal to the sum of the addendum of the two meshing gears.
14. Tooth thickness. It is the width of the tooth measured along the pitch circle.
15. Tooth space. It is the width of space between the two adjacent teeth measured along the pitch circle.
16. Backlash. It is the difference between the tooth space and the tooth thickness, as measured along the
pitch circle. Theoretically, the backlash should be zero, but in actual practice, some backlash must be
allowed to prevent jamming of the teeth due to tooth errors and thermal expansion.
17. The face of a tooth. It is the surface of the gear tooth above the pitch surface.
18. The flank of the tooth. It is the surface of the gear tooth below the pitch surface.
19. Top land. It is the surface of the top of the tooth.
20. Face width. It is the width of the gear tooth measured parallel to its axis.
21. Fillet It is the curved portion of the tooth flank at the root circle.
22. Circular pitch. It is the distance measured on the circumference of the pitch circle from point of one
tooth to the corresponding point on the next tooth.
It is usually denoted by pc .
Mathematically,
d
Circular pitch, pc 
T
Where d= Diameter of the pitch circle, and
T = Number of teeth on the wheel.
The angle subtended by the circular pitch at the center of the pitch circle is known as the pitch angle.

23. Module (m). It is the ratio of the pitch diameter in mm to the number of teeth.
d
m
T
d
Also pc   m
T
 Pitch of two mating gear must be the same.
24. Diametral Pitch (P)It is the number of teeth per unit length of the pitch circle diameter in inch.
OR
It is the ratio of no. of teeth to pitch circle diameter in inch.
T
Pd 
d
 The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12,
16, and 20. The modules 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14 and 18 are of second
choice.
25. Gear Ratio (G). It is the ratio of the number of teeth on the gear to that on the pinion.
T
G Where T= No of teeth on a gear
t
t = No. of teeth on the pinion
26. Velocity Ratio (VR) The velocity ratio is defined as the ratio of the angular velocity of the follower to
the angular velocity of the driving gear.
2 N2 d1 T1
VR    
1 N1 d2 T2
27. Length of the path of contact. It is the length of the common normal cut-off by the
Addendum circles of the wheel and pinion.
OR
The locus of the point of contact of two mating teeth from the beginning of the engagement to the end of
engagement is known as the contact.
a. Path of Approach Portion of the path of contact from the beginning of the engagement to
the pitch point.
b. Path of Recess Portion of the path of contact from the pitch point to the end of the
engagement.
28. Arc of Contact The locus of a point on the pitch circle from the beginning to the end of the engagement
of two mating gears is known as the arc of contact.
a. Arc of Approach It is the portion of the arc of contact from the beginning of the engagement
to the pitch point.
b. Arc of Recess The portion of the arc of contact from the pitch point to the end of
engagements the arc of recess.
29. The angle of Action (𝜹) It is the angle turned by gear from the beginning of the engagement to the end
of engagement of a pair of teeth, i.e., the angle turned by arcs of contact of respective gear wheels.
     Where  =Angle of approach
 =Angle of recess
30. Contact ratio. It is the angle of action divided by the pitch angle
  
Contact ratio  
 
OR
Arcof contact
Contact ratio 
Circularpitch
7.2.1 Condition for Constant Velocity Ratio of Toothed Wheels – Law of Gearing
To understand the theory consider the portions of two gear teeth gear 1 and gear 2. The two teeth come
in contact at point C and the direction of rotation of gear 1 is anticlockwise & gear 2 is clockwise.
Let TT be the common tangent & NN be the common normal to the curve at the point of contact C. From
points O, & O2, draw O1A & O2B perpendicular to common normal NN. When the point D is considered on
gear 1, the point C moves in the direction of “CD” & when it is considered on gear 2. The point C moves in
the direction of “CE”.
Fig.7.11 – Law of gearing

The relative motion between tooth surfaces along the common normal NN must be equal to zero in order
to avoid separation. So, relative velocity
𝑉1 cos 𝛼 = 𝑉2 cos 𝜃
(ω1 × 𝑂1 𝐶) cos 𝛼 = (ω2 × 𝑂2 𝐶) cos 𝜃 (∵ 𝑉 = 𝑟 𝜔) Eq. (7.1)
O1 A
But from  O1 AC, cos  
O1 C
O2 B
and from  O2 BC, cos  
O2 C

Putting the above value in Eq. (7.1) it becomes
𝑂1 𝐴 𝑂2 𝐵
(ω1 × 𝑂1 𝐶) = (ω2 × 𝑂2 𝐶)
𝑂1 𝐶 𝑂2 𝐶
∴ (ω1 × 𝑂1 𝐴) = (ω2 × 𝑂2 𝐵)
ω1 𝑂2 𝐵 Eq. (7.2)
∴ =
ω2 𝑂2 𝐴
From a similar triangle  O1 AP &  O2 BP

𝑂2 𝐵 𝑂2 𝑃 Eq. (7.3)
=
𝑂2 𝐴 𝑂2 𝑃
Equating Eq. (7.2) and Eq. (7.3)
1 O2 B O P PB
  2 
2 O1 A O1 P AP
From the above, we can conclude that the angular velocity ratio is inversely proportional to the ratio of the
distances of the point P from the central O1& O2.
If it is desired that the angular velocities of two gear remain constant, the common normal at the point of
contact of two teeth always passes through a fixed point P. This fundamental condition is called as law
of gearing which must be satisfied while designing the profiles of teeth for gears.
7.2.2 Standard Tooth Profiles or Systems

Following four types of tooth profiles or systems are commonly used in practice for interchangeability:
1
a) 14 composite system
2
1
b) 14 full depth involute system
2
c) 20 full depth involute system
d) 20 stub involute system
1
a) 14 composite system:
2
This type of profile is made with circular arcs at the top and bottom portion and the middle portion is a
straight line. The straight portion corresponds to the involute profile and the circular arc portion
corresponds to the cycloidal profile. Such profiles are used for general purpose gears.
1
Fig.7.12 - 14 composite system
2

1
b) 14 full depth involute system:
2
1
Fig.7.13 - 14 full depth involute system
2
This type of profile is made straight line except for the fillet arcs. The whole profile corresponds to the
involute profile. Therefore manufacturing of such profiles is easy but they have interface problems.
c) 20 full depth involute system:
Fig.7.14 - 20 full depth involute system
1
This type of profile is the same as 14 the full depth involute system except for the pressure angle. The
2
1
increase of pressure angle from 14 to 20 results in a stronger tooth, since the tooth acting like a beam,
2
is wider at the base. This type of gears also has an interference problem if the number of teeth is less.
d) 20 stub involute system:
Fig.7.15 - 20 stub involute system

The problem of interference in 20 full depth involute system is minimized by removing extra addendum
of gear tooth which causes interference. Such a modified tooth profile is called “Stub tooth profile”. This
type of gears is used for heavy load.
7.3 Length of Path of Contact And Length of Arc of Contact
7.3.1 Length of Path of Contact
Fig.7.16 - Length of Path of Contact
 When the pinion rotates in the clockwise direction, the contact between a pair of involute teeth
begins at K (on the flank near the base circle of pinion or the outer end of the tooth face on the
wheel) and ends at L (on the flank near the base circle of the wheel).
 MN is the common normal at the point of contact and the common tangent to the base circles.
 The point K is the intersection of the addendum circle of the wheel and the common tangent.
 The point L is the intersection of the addendum circle of pinion and common tangent.
 The length of the path of contact is the length of the common normal cutoff by the addendum
circles of the wheel and the pinion.
 Thus the length of the path of contact is KL which is the sum of the parts of the path of contacts
KP and PL. The part of the path of contact KP is known as the path of approach and the part of the
path of contact PL is known as the path of recess.
L.P.C  KL
 KP  PL
where, KP = path of approach
PL = path of recess

Let,
R = O2P = pitch circle radius of wheel
RA = O2K = addendum circleradius of wheel
r = O1P = pitch circle radius of pinion
rA = O1L = addendumcircleradius of pinion
Length of the path of contact = Path of approach + path of recess
= KP  PL
 KN  PN  ML  MP 
  O2K2  O2N2  PN    O1L2  O1M2  MP 

 R A
2
 Rcos ø   Rsin ø 
2
 rA2  rcos ø   rsin ø
2

7.3.2 Length of Arc of Contact
 The arc of contact is the path traced by a point on the pitch circle from the beginning to the end of
the engagement of a given pair of teeth.
 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 the arc of recess.
 The angles subtended by these arcs at O1 are called angle of approach and angle of recess
respectively.
Length of the arc of contact GPH   GP  PH 
 Arc of approach  Arc of recess

KP PL
 
cos ø cos ø
KP  PL KL
 
coscos ø cos ø
Length of path of contact

cos ø
7.3.3 Contact Ratio (or Number of Pairs of Teeth in 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
Length of arc of contact


Circular pitch

πm

Notes:
 For continuous transmission of the motion, at least one tooth of anyone wheel must be in contact
with another tooth of the second wheel so ‘n’ must be greater than unity.
 If ‘n’ lies between 1& 2, no. of teeth in contact at any time will not be less than one and will never
mate two.
 If ‘n’ lies between 2 & 3, it is never less than two pairs of teeth and not more than three pairs and
so on.
 If ‘n’ is 1.6, one pair of teeth are always in contact whereas two pair of teeth are in contact for 60%
of the time.
7.4 Interference in Involute Gears
Fig.7.17 - Interference in involute gears
 A pinion with centerO1, in mesh with wheel or gear with centreO2. MN is the common tangent to
the base circles and KL is the path of contact between the two mating teeth.
 A little consideration will show that if the radius of the addendum circle of pinion is increased to
O1N, 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 the tooth on the pinion will then undercut the tooth on the wheel at the root and
remove part of the involute profile of the 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 the tooth
undercuts the root on its mating gear is known as interference.
 Similarly, if the radius of the addendum circles of the wheel increases beyond O2M, then the tip of
the tooth on the wheel will cause interference with the tooth on pinion.
 The points M and N are called interference points. 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 O1N and the wheel is O2M.

7.4.1 How to avoid interference?
 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.
OR
 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.
When interference is just avoided, the maximum length of the path of contact is MN.
The maximum length of the path of contact  MN
 MP  PN
 r sinø  R sinø
  r  R  sinø
The maximum length of the arc of contact 

r  R  sinø
cosø
Notes:
In case the addenda on pinion and wheel are such that the path of approach and path of recess are
half of their maximum possible values, then
1
Path of approach, KP = MP
2
 1

RA2  Rcos ø   Rsin ø  rsinø
2
2
1
Path of recess, PL  PN
2
 
1
rA2  rcos ø   rsin ø  Rsinø
2
2
Length of the path of contact KP  PL
1 1
 MP  PN
2 2

 r  R  sinø
2
7.4.2 Minimum Number of Teeth on the Pinion in Order to Avoid Interference

 In order to avoid interference, the addendum circles for the two mating gears must cut the common
tangent to the base circles between the points of tangency.
 The limiting condition reaches when the addendum circles of pinion and wheel pass-through point
N and M respectively.
Let t = Number of teeth on the pinion,
T = Number of teeth on the wheel,
m = Module of the teeth,
r = Pitch circle radius of pinion = mt/ 2
G = Gear ratio = T / t = R / r
ø = Pressure angle or angle of obliquity.
From ∆ O1NP,
O1N 2  O1P 2  PN2  2OP  PNcos O1PN 
O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

2
O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

2
O1N2  r2  R2 sin2 ø  2rRsin2 ø
 R2 sin2 ø 2Rsin2 ø 
O1N2  r2 1   
 r2 r 
 R2 sin2 ø 2Rsin2 ø 
O1N2  r2 1   
 r2 r 
 RR  
O1N2  r2 1    2  sin2 ø 
 rr  
RR 
O1N  r 1    2  sin2 ø
rr 
mt RR 
O1N  1    2  sin2 ø
2 rr 
Let Ap  m = Addendum of the pinion, where AP is a fraction by which the standard addendum of
one module for the pinion should be multiplied in order to avoid interference.
Addendum of the pinion  O1N– O1P
mt TT  mt
AP .m  1    2  sin2 ø 
2 tt  2
mt TT  mt
 AP .m  1    2  sin2 ø 
2 tt  2
mt  T T  2 
 AP .m   1    2  sin ø  1
2  tt  
mt  T T  2 
 AP .m   1    2  sin ø  1
2  tt  
t TT  
 AP .   1    2  sin2 ø  1
2  tt  

t TT  
 AP   1    2  sin2 ø  1
2  tt  
t TT  
 AP   1    2  sin2 ø  1
2  tt  
2 AP
t 
 TT  2 
 1    2  sin ø  1
 tt  
2AP
t 
 1  G  G  2  sin2 ø  1
 
Note:
If the pinion and wheel have equal teeth, then G = 1.
2AP
t 
 1  3sin2 ø  1
 
Table 7.1 - Min. no of teeth on pinion
Sr. No. System of Gear Tooth Min. no. of teeth on the pinion
1
1 14 ° Composite 12
2
1
2 14 2 °Full depth involute 32
3 20° Full-depth involute 18
4 20°Stub involute 14
7.4.3 Minimum Number of Teeth on the Wheel in Order to Avoid Interference

Let T = Minimum number of teeth required on the wheel in order to avoid interference,
Aw  m = Addendum of the wheel, where AW is a fraction by which the standard
The addendum for the wheel should be multiplied.

From ∆O2MP
O2M2  O2P2  PM2  2O2P  PMcos  O2PM
O2M2  R2  rsinø   2r Rsinø   cos  90  ø 

2
O2M2  R2  r2 sin2 ø  2rRsin2 ø
 r2 sin2 ø 2rsin2 ø 
O2M2  R2 1  
 R2 R 

 rr  
O2M2  R2 1    2  sin2 ø 
 RR  
rr 
O2M  R 1    2  sin2 ø
RR 
mT rr 
O2M  1    2  sin2 ø
2 RR 
Addendum of the wheel  O2M – O2P
mT tt  mT
Aw m  1    2  sin2 ø 
2 TT  2
mT  tt  2 
 Aw m   1    2  sin ø  1
2  TT  
mT  tt  2 
 Aw m   1    2  sin ø  1
2  TT  
T tt  
 Aw   1    2  sin2 ø  1
2  TT  
2 Aw
T 
 tt  2 
 1    2  sin ø  1
 TT  
2Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
Note:
From the above equation, we may also obtain the minimum number of teeth on the pinion. Multiplying
both sides by t/T,
t
2 Aw 
t T
T 
T  11  2 
 1    2  sin ø  1
 G G  
2 Aw
t 
 11  
G  1    2  sin2 ø  1
 G G  
If wheel and pinion have equal teeth, then G = 1,
2Aw
T 
 1  3sin2 ø  1
 
7.4.4 Minimum Number of Teeth on a Pinion for Involute Rack in Order to Avoid Interference
Fig.7.18 - Rack, and pinion in mesh
Let t = Minimum number of teeth on the pinion,

m t
r = Pitch circle radius of the pinion = and
2
ø= Pressure angle or angle of obliquity, and
AR  m = Addendum for the rack, where AR is the fraction by which the standard addendum of one
module for the rack is to be multiplied.
Addendum for the rack, AR  m  LH
 AR  m  PL sin 
 AR  m  r sin φ  sin φ
 AR  m  r sin2φ
mt sin2φ
 AR  m 
2
2A
t  2 R
sin φ
Note:
In the case of pinion, max. value of addendum radius to avoid interference if AF
 O2M2  AF2
 rcos ø   Rsinø  rsinø 

2 2
Max value of addendum of the pinion is

RR 
A 
p max  r 1    2  sin2 ø  1
rr 
mt 
 1  G  G  2  sin2 ø  1
2  

7.5 Comparison of Cycloidal and Involute tooth forms
Table 7.2 - Comparison of Cycloidal and Involute tooth forms
Cycloidal teeth Involute teeth
Pressure angle varies from a maximum at the The pressure angle is constant throughout the
beginning of the engagement, reduces to zero engagement of teeth. This results in the
at the pitch point and again increases to a smooth running of the gears.
maximum at the end of the engagement
resulting in the smooth running of gears.
It involves double curves for the teeth, It involves the single curves for the teeth
epicycloid, and hypocycloid. This complicates resulting in simplicity of manufacturing and of
the manufacturer. tool
Owing to the difficulty of the manufacturer, These are simple to manufacture and thus are
these are costlier. cheaper.
Exact center distance is required to transmit a A little variation in a center distance does not
constant velocity ratio. affect the velocity ratio.
The phenomenon of interference does not Interference can occur if the condition of
occur at all. minimum no. of teeth on a gear is not followed.
The teeth have spreading flanks and thus are The teeth have radial flanks and thus are
stronger. weaker as compared to the Cycloidal form for
the same pitch.
In this, a convex flank always has contact with Two convex surfaces are in contact and thus
a concave face resulting in less wear. there is more wear.
7.6 Helical and Spiral Gears
Fig.7.19 – Helical Gear
 A helical gear has teeth in the form of the helix around the gear. Two such gears may be used to
connect two parallel shafts in place of the spur gear. The helixes may be right-handed on one wheel
and left-handed on the other.
 The pitch surfaces are cylindrical as in spur gearing, but the teeth instead of being parallel to the
axis, wind around the cylinders helically like screw threads.
 The teeth of helical gears with parallel axis have line contact, as in spur gearing. This provides
gradual engagement and continuous contact of the engaging teeth. Hence helical gears give
smooth drive with high efficiency of transmission.
 The helical gears may be of the single helical type or double helical type. In the case of single
helical gears, there is some axial thrust between the teeth, which is a disadvantage.
 In order to eliminate this axial thrust, double helical gears are used. It is equivalent to two single
helical gears, in which equal and opposite thrusts are produced on each gear and the resulting axial
thrust is zero.
 The following definitions may be clearly understood in connection with a helical gear:
1. Normal pitch. It is the distance between similar faces of adjacent teeth, along a helix on the pitch
cylinder normal to the teeth. It is denoted by pN.
2. Axial pitch. It is the distance measured parallel to the axis, between similar faces of adjacent
teeth. It is the same as circular pitch and is therefore denoted by pc. If α is the helix angle, then
pN
Circular pitch, pc 
Cos
Note: The helix angle is also known as the spiral angle of the teeth.
7.6.1 The efficiency of Spiral Gears

A pair of spiral gears 1 and 2 are in mesh. Let the gear 1 be the driver and the gear 2 the driven. The forces
acting on each of a pair of teeth in contact. The forces are assumed to act at the center of the width of
each teeth and in the plane tangential to the pitch cylinders
Fig.7.20 - Efficiency of Spiral Gears

Let F1 = Force applied tangentially on the driver,
F2 = Resisting force acting tangentially on the driven,
Fa1 = Axial or end thrust on the driver,
Fa2 = Axial or end thrust on the driven,
RN = Normal reaction at the point of contact
 = Angle of friction,
R = Resultant reaction at the point of contact, and
 = Shaft angle =1 +2
...( Both gears are of the same hand)
From triangle OPQ, F1 = R cos  1   
 Work input to the driver = F1  d1  N1  Rcos  1     d1  N1
From triangle OST, F2  Rcos(2  )
 Work output of the driven = F2  d2  N2  Rcos   2     d2  N2
Efficiency of spiral gears,
Work output Rcos  2     d2  N2

 
Work input Rcos  1     d1  N1
cos  2     d2  N2

cos  1     d1  N1
Pitch circle diameter of gear 1,

pc1  T1 pN T
d1    1
 Cos1 
Pitch circle diameter of gear 2,

pc2  T2 pN T
d2    2
 Cos2 
d2 T2Cos1
  (2)
d1 T1Cos2
N2 T1
 (3)
N1 T2
Multiplying equation (2) and (3) we get

d2N2 cos 1

d1N1 cos 2
Substituting this value in equation (1)
cos  2    cos 1
 (4)
cos  1    cos 2

cos  1  2     cos  1  2   

cos  1  2     cos  1  2   
 1 
 cos A  cosB  cos  A  B   cos  A  B   
 2 
cos       cos  1   2   
 (5)
cos       cos  1   2   
   1   2 
Since the angle  and  are constants, therefore the efficiency will be maximum, when cos  1  2   
is maximum, i.e. cos  1  2    =1
1  2    0
1  2   and 2  1  
Since 1  2   therefore

1    2    1   OR 1 
2

Similarly 2 
2
Substituting 1  2   and 2  1   in equation (5) we get
cos       1
max 
cos       1
7.7 Introduction to Gear Trains and Its Classification

When two or more gears are made to mesh with each other to transmit power from one shaft to another.
Such a combination is called gear train or train of toothed wheels.
The nature of the train used depends upon the velocity ratio required and the relative position of the axes
of shafts. A gear train may consist of a spur, bevel or spiral gears.
Types of Gear Trains
1. Simple gear train
2. Compound gear train
3. Reverted gear train
4. Epicyclic gear train
5. Compound epicyclic gear train
7.7.1 Simple gear train

When there is only one gear on each shaft, it is known as a simple gear train. The gears are represented
by their pitch circles. When the distance between the two shafts is small, the two gears 1 and 2 are made
to mesh with each other to transmit motion from one shaft to the other. Since the gear 1 drives the gear
2, therefore gear 1 is called the driver and the gear 2 is called the driven or follower. It may be noted that
the motion of the driven gear is opposite to the motion of driving gear.

Fig.7.21 - Simple gear train
Let,
N1  Speedof driver rpm
N2  Speedofintermediatewheel rpm
N3  Speedof follower rpm
T1  Number of teethon driver
T2  Number of teethonintermediatewheel
T3  Number of teethonfollower
Since the driving gear, 1 is in mesh with the intermediate gear 2, so speed ratio for these two gears is
N1 T2
 (1)
N2 T1
As the intermediate gear, 2 is in mesh with the driven gear 3, so speed ratio for these two gears is
N2 T3
 (2)
N3 T2
The speed ratio of the gear train is obtained by multiplying the equations (1) and (2).
N1 N2 T2 T3
  
N2 N3 T1 T2
N T
 1 3
N3 T1
Sometimes, the distance between the two gears is large. The motion from one gear to another, in such a
case, maybe transmitted by either of the following two methods:
1. By providing the large-sized gear, or
 A little consideration will show that this method (i.e. providing large-sized gears) is a very
inconvenient and uneconomical method.
2. By providing one or more intermediate gears.
 This method (i.e. providing one or more intermediate gear) is very convenient and economical.
It may be noted that when the number of intermediate gears is odd, the motion of both the gears (i.e. driver
and driven or follower) will rotate in the same direction.
If the numbers of intermediate gears are even, the motion of the driven or follower will be in the opposite
direction of the driver.
 Speed ratio (or velocity ratio) of the gear train is the ratio of the speed of the driver to the speed of the
driven or follower and the ratio of speeds of any pair of gears in the mesh is the inverse of their number
of teeth.
N1 T2
Speedratio  
N2 T1

 The train value of the gear train is the ratio of the speed of the driven or follower to the speed of the
driver.
N2 T1
Trainvalue  
N1 T2
7.7.2 Compound Gear Train

When there is more than one gear on a shaft, it is called a compound train of gear.
Fig.7.22 - Compound Gear Train

The idle gears, in a simple train of gears, do not affect the speed ratio of the system. But these gears are
useful in bridging over the space between the driver and the driven.
But whenever the distance between the driver and the driven or follower has to be bridged over by
intermediate gears and at the same time a great (or much less) speed ratio is required, then the advantage
of intermediate gears is intensified by providing compound gears on intermediate shafts.
In this case, each intermediate shaft has two gears rigidly fixed to it so that they may have the same speed.
One of these two gears meshes with the driver and the other with the driven or follower attached to the
next shaft.
In a compound train of gears, the gear 1 is the driving gear mounted on shaft A; gears 2 and 3 are
compound gears which are mounted on shaft B. The gears 4 and 5 are also compound gears which are
mounted on shaft C and the gear 6 is the driven gear mounted on shaft D.
Let,
N1 = Speed of driving gear 1,
T1 = Number of teeth on driving gear 1,
N2 ,N3 ..., N6 = Speed of respective gears in r.p.m., and
T2 ,T3..., T6 = Number of teeth on respective gears.
Since gear 1 is in mesh with gear 2, therefore its speed ratio is
N1 T2
 (1)
N2 T1
Similarly, for gears 3 and 4, the speed ratio is
N3 T4
 (2)
N4 T3

And for gears 5 and 6, speed ratio is
N5 T6
 (3)
N6 T5
The speed ratio of the compound gear train is obtained by multiplying the equations (1), (2) and (3),
N1 N3 N5 T2 T4 T6
    
N2 N4 N6 T1 T3 T5
The advantage of a compound train over a simple gear train is that a much larger speed reduction from
the first shaft to the last shaft can be obtained with small gears. If a simple gear train is used to give a
large speed reduction, the last gear has to be very large. Usually, for a speed reduction in excess of 7 to 1,
a simple train is not used and a compound train or worm gearing is employed.
7.7.3 Reverted Gear Train
Fig.7.23 - Reverted Gear Train

When the axes of the first gear (i.e. first driver) and the last gear (i.e. last driven or follower) are co-axial,
then the gear train is known as a reverted gear train.
Gear 1 (i.e. first driver) drives the gear 2 (i.e. first driven or follower) in the opposite direction. Since the
gears 2 and 3 are mounted on the same shaft, therefore they form a compound gear and the gear 3 will
rotate in the same direction as that of gear 2.
The gear 3 (which is now the second driver) drives the gear 4 (i.e. the last driven or follower) in the same
direction as that of gear 1. Thus we see that in a reverted gear train, the motion of the first gear and the
last gear is like.
Let,
T1  Number of teeth on gear 1,
r1  Pitch circle radius of gear 1, and
N1  Speed of gear 1 in r.p.m.
Similarly,
T2, T3, T4  Number of teeth on respective gears,
r2, r3, r4  Pitch circle radii of respective gears, and
N2, N3, N4  Speed of respective gears in r.p.m.

Since the distance between the centers of the shafts of gears 1 and 2 as well as gears 3 and 4 is the same,
therefore
r1  r2  r3  r4
Also, the circular pitch or module of all the gears is assumed to be the same; therefore the number of teeth
on each gear is directly proportional to its circumference or radius.
T1  T2  T3  T4
Product of number of teeth on drivens
Speedratio 
Product of number of teeth on drivers
N1 T2  T4

N4 T1  T3
Applications:
The reverted gear trains are used in automotive transmissions, lathe back gears, industrial speed reducers,
and in clocks (where the minute and hour hand shafts are co-axial).
7.7.4 Epicyclic Gear Train
Fig.7.24 - Epicyclic Gear Train

In an epicyclic gear train, the axes of the shafts, over which the gears are mounted, may move relative to
a fixed axis. A gear A and the arm C have a common axis at O1 about which they can rotate. The gear B
meshes with gear A and has its axis on the arm at O2, about which the gear B can rotate.
If the arm is fixed, the gear train is simple and gear A can drive gear B or vice- versa, but if gear A is fixed
and the arm is rotated about the axis of gear A (i.e. O1), then the gear B is forced to rotate upon and around
gear A.
Such a motion is called epicyclic and the gear trains arranged in such a manner that one or more of their
members move upon and around another member is known as epicyclic gear trains (epi. means upon and
cyclic means around). The epicyclic gear trains may be simple or compound.
Applications:
The epicyclic gear trains are useful for transmitting high-velocity ratios with gears of moderate size in a
comparatively lesser space. The epicyclic gear trains are used in the back gear of lathe, differential gears
of the automobiles, hoists, pulley blocks, wristwatches, etc.

Table 7.3 - Table of Motions
Step Revolution of Elements

Condition of Motion
No. Arm C Gear A Gear B
TA
1 Arm fixed - gear A rotates +1 revolution (anticlockwise) 0 +1 
TB
TA
2 Arm fixed - gear A rotates through + x revolutions 0 x x
TB
3 Add + y revolutions to all elements y y y
TA
4 Total motion y x y y- x
TB
Applications:
The epicyclic gear trains are useful for transmitting high-velocity ratios with gears of moderate size in a
comparatively lesser space. The epicyclic gear trains are used in the back gear of lathe, differential gears
of the automobiles, hoists, pulley blocks, wristwatches, etc.
7.7.5 Compound Epicyclic Gear Train—Sun and Planet Gear

A compound epicyclic gear train consists of two co-axial shafts S1 and S2, an annulus gear A which is
fixed, the compound gear (or planet gear) B-C, the sun gear D, and the arm H. The annulus gear has internal
teeth and the compound gear is carried by the arm and revolves freely on a pin of the arm H. The sun gear
is co-axial with the annulus gear and the arm but independent of them.
The annulus gear A meshes with the gear B and the sun gear D meshes with the gear C. It may be noted
that when the annulus gear is fixed, the sun gear provides the drive and when the sun gear is fixed, the
annulus gear provides the drive. In both cases, the arm acts as a follower.
Note: The gear at the center is called the sun gear and the gears whose axes move are called planet gears.
Let TA, TB, TC, and TD be the teeth and NA, NB, NC, and ND be the speeds for the gears A, B, C, and D
respectively. A little consideration will show that when the arm is fixed and the sun gear D is turned
anticlockwise, then the compound gear B-C and the annulus gear A will rotate in the clockwise direction.
Table 7.4 - Table of motions
Revolution of Elements
Step
Conditions of motion Gear Compound Gear
No. Arm Gear A
D (B-C)
Arm fixe, gear D rotates +1 revolution TD TD TB

1 0 +1   
(anticlockwise) TC TC TA
Arm fixed gear D rotates through + x TD TD TB

2 0 +x x x 
revolutions TC TC TA
3 Add + y revolutions to all elements +y +y +y +y
TD TD TB
4 Total motion +y xy yx yx 
TC TC TA

7.8 Problems
Ex. 7.1 Two spur gears have a velocity ratio of 1/3 the driven gear has 72 teeth of 8 mm module
and rotates at 300 RPM. Calculate the number of teeth and Speed of driver. What will be
the pitch line velocity?
Solution: Given data Find
VR  1 / 3 Vp  ?
T2  72 teeth T1  ?
m  8 mm
N2  300
N2 T1
VR  
N1 T2
1 300 T1
  
3 N1 72
 T1  24 &N1  900 rpm
Pitch line velocity,
VP  r11  r22
2N1 d1
 
60 2
2N1 mT1
 
60 2
2 900 8  24
 
60 2
 9047.78 mm / sec
Ex. 7.2 The number of teeth of spur gear is 30 and it rotates at 200 RPM. What will be its circular
pitch and the pitch line velocity if it has a module of 2 mm?
Solution: Given data Find:
T  30 Pc  ?
N  200 rpm Vp  ?
m  2 mm
Circular pitch, Pc   m
  2
 6.28mm

Pitch line velocity, Vp   r
2N d
 
60 2
2 200 2  30
 
60 2
 628.3mm / s
Ex. 7.3 The following data relate to two meshing gears velocity ratio = 1/3, module = 1mm,
Pressure angle 20°, center distance= 200 mm. Determine the number of teeth and the
base circle radius of the gear wheel.
VR  1 / 3 T1  ?
Ø  20 T2  ?
C  200 mm Base circle radius of gear wheel  ?
m  4 mm
N 2 1 T1
VR   
N1 3 T2
T2  3T1 (1)
d1  d 2
Center distance C 
2
m T1  T2   d
 200   m 
2  2
4 T1  T2 
 200 
2
T1  T2  100 (2)
By solving equation (1) & (2)
T1  25
T2  75
No of teeth of the gear wheel T2  75
d2
But m 
T2
d2  mT2
d2  300mm
d2
Base circle radius db2  cos 
2
300
  cos20
2
 141mm

Ex. 7.4 Each of the gears in a mesh has 48 teeth and a module of 8 mm. The teeth are of a 20°
involute profile. The arc of' contact is 2.25 times the circular pitch. Determine the
addendum.
T  t  48 Addendum  ?
m  8 mm
ø  20
Arc of contact  2.25 Pc
Arc of contact  2.25Pc
 2.25m
 2.25 8
 56.55mm
d 2r
Let, m  
t T
mT 8  48
R  r  
2 2
R  r  192mm
Also, Ra  ra ( toothsizesame)
L.P.C
L.A.C 
COS
L.P.C
 56.55 
COS20
 L.P.C  53.14 mm
L.P.C  R A
2
r
 Rcosø   Rsinø 
2
A
2
 rcosø   rsinø
2

53.14  2  RA2  Rcoscosø    R+r  sinø  RA  rA 
2
 
53.14  2  RA2  192cos20    192  192  sin20

2
 
 53.14  2  RA2  32551.73   131.33

 
 RA2  32551.73  92.23mm

RA  202.63mm
Now RA  R  Addendum
Addendum  RA  R
 Addendum  10.63mm

Ex. 7.5 Two involute gears in mesh have a 20° pressure angle. The gear ratio is 3 and the number
of teeth on the pinion is 24. The teeth have a module of 6 mm. The pitch line velocity is
1.5 m/s and the addendum equal to one module. Determine the angle of action of a pinion
(the angle turned by the pinion when one pair of teeth is in the mesh) and the maximum
velocity of sliding.
Ø  20 Angle of action of the pinion  ?
G  T/t  3 Max. velocity of sliding  ?
t  24
m  6 mm
Vp  1.5 m / s
Addendum  1 module
mt 6  24 mT 6  72
r   72mm R   216mm
2 2 2 2
 T  24  3  72 
ra  r  Add.  72  (1  6)  78mm RA  R  Add.  216  (1  6)  222mm
Let the length of the path of contact KL  KP  PL
KP  R A
2
 Rcosø   Rsinø
2

 
  2222   216cos20 
2
 216sin20 
 
 16.04mm
PL  rA
2
2

 
  782   72cos20 
2
 72 sin20 
 
 14.18mm
Pathof contact
Arcof contact 
cos
16.04  14.18

cos20
 32.16mm
Lengthof arcof contact  360
Angleturnedthroughbypinion( ) 
circumferenceofpinion
32.16  360

2 72
 25.59
Max.velocityof sliding  (p  g )  KP
V V
     KP  V  r
r R
 1500 1500 
    16.04
 72 216 
 445.6mm / sec
Ex. 7.6 Two involute gears in a mesh have a module of 8 mm and a pressure angle of 20°. The
larger gear has 57 while the pinion has 23 teeth. If the addendum on pinion and gear
wheels are equal to one module, Determine
i. Contact ratio (No. of pairs of teeth in contact )
ii. The angle of action of pinion and gear wheel
iii. The ratio of sliding to the rolling velocity at the
a. Beginning of the contact.
b. Pitch point.
c. End of the contact.

Ø  20 1. Contact ratio  ?
m  8 mm 2. Angle of action of pinion and gear  ?
T  57 3. Ratio of sliding to rolling velocity at the
t  23 a. Beginning of contact
Addendum  1 module b. Pitch point
 8 mm c. End of contact
i. Let the length of the path of contact KL = KP +PL
KP = R A
2
- Rcosø  - Rsinø
2

 
=  2362 -  228cos20o  - 228sin20o 
2
 
= 20.97 mm
PL =  rA 2 -  rcosø  - rsinø
2

 
  1002   92cos20 
2
 92sin20 
 
= 18.79mm
Pathof contact
Arcof contact 
cos
KP  KP

cos
20.97  18.79

cos20
 42.29mm
Lengthof arcof contact
Contactratio 
Pc
42.21
  1.68 say 2
m
ii.
Angleof actionofpinion(p ) 
circumferenceofpinion
42.31  360

2 92
 26.34
Angleof actionofpinion(g ) 
circumferenceof gear
42.31  360

2 228
 10.63
iii. The ratio of sliding to rolling velocity:
a. Beginning of contact
Slidingvelocity  p  g KP

Rollingvelocity pr
 92 
 p  P   20.97

228 
p  92
 0.32
b. Pitch point
Slidingvelocity  p  g KP



p  g   0
pr
0
c. End of the contact
Slidingvelocity  p  g PL

 92 
 p  P   18.79

228 
p  92
 0.287
Ex. 7.7 Two 20° gears have a module pitch of 4 mm. The number of teeth on gears 1 and 2 is 40
and 24 respectively. If the gear 2 rotates at 600 rpm, determine the velocity of sliding
when the contact is at the tip of the tooth of gear 2. Take addendum equal to one module.
Also, find the maximum velocity of sliding.

Ø  20 Velocity of sliding  ?
m  4 mm Max. velocity of sliding  ?
Np  600 rpm
T  40
t  24
Addendum  1 module
 4 mm
mt 4  24 mT 4  40
r   48mm R   80mm
2 2 2 2
ra  r  Add.  48  (1  4)  52mm RA  R  Add.  80  (1  4)  84mm
(Note: The tip of the driving wheel is in contact with a tooth of driving wheel at the end of
the engagement. So it is required to find the path of recess.)
Path of recess,
PL  r
A
2
2

 
  522   48cos20 
2
 48sin20 
 
 9.458mm
The velocity of sliding,
 (p  g )  PL
2
  600  360   9.458
60
 Ng t 24 
   Ng  600   360rpm 
 NP T 40 
 956.82mm / sec
Path of recess,
KP  R A
2
2

 
  842   80cos20 
2
 80 sin20 
 
 10.108mm
Max. Velocity of sliding,
  p  g   KP
2
 (600  360)  10.108
60
 1016.16mm / sec
Ex. 7.8 Two 20° involute spur gears mesh externally and give a velocity ratio of 3. The module is
3 mm and the addendum is equal to 1.1 module. If the pinion rotates at the 120 rpm,
determine a minimum no of teeth on each wheel to avoid interference and contact ratio.

Ø  20 tmin & Tmin  ?
VR  3 Contact ratio  ?
m  3
NP  120
Addendum  1.1 module
2A w
I. T
 11  2 
 1    2  sin ø  1
 G G  
2  1.1
T 
 1 1  2 
 1    2  sin 20  1
 3 3  
 T  49.44 teeth
T 51
 T  51teeth And t   17teeth
3 3
II.
mt 3  17 mT 3  51
r   25.5mm R    76.5mm
2 2 2 2
ra  r  Add.  25.5  (1.1  3)  28.8mm RA  R  Add.  76.5  (1.1  3)  28.8mm
Lengthofpathofcontact
Contactratio 
cos   Pc
 R A
2
 Rcosø   Rsinø 
2
r A
2
2

cos20   3
   
 79.8   76.5cos20   76.5sin20    28.82  25.5cos0 
2 2
2
 25.5sin20 
   
cos20   3
 1.78
Thus 1 pair of teeth will always remain in contact whereas, for 78 % of the time, 2 pairs of
teeth will be in contact.
Ex. 7.9 Two involute gears in a mesh have a velocity ratio of 3. The arc of approach is not to be
less than the circular pitch when the pinion is the driver The pressure angle of the involute
teeth is 20°. Determine the least no of teeth on each gear. Also, find the addendum of the
wheel in terms of module.
Ø  20 least no of teeth on the each gear  ?
VR  3 Addendum  ?

Arc of approach = Circular pitch   m
Pathof approach  Arcof approach  cos20
  m  cos20
 2.952m (1)
Let the max lengthofpathof approach  rsin
mt
 sin20
2
 0.171mt (2)
From eq. 1. and 2,
0.171mt  0.2952m
 t  17.26  18 teeth
T  18  3  54 teeth
Max. Addendum of the wheel,
mt  11  2 
A wmax   1    2  Sin   1
2  G G  
m  54  11  2 
  1    2  Sin 20  1
2  3 3  
 1.2m
Ex. 7.10 Two 20° involute spur gears have a module of 10 mm. The addendum is equal to one
module. The larger gear has 40 teeth while the pinion has 20 teeth will the gear interfere
with the pinion?
Solution: Given Data:
Ø = 20°
m = 10 mm
Addendum = 1 module
 110
 10mm
To be Calculated: Interference or not?
Let the pinion is the driver,
t = 20 teeth
T = 40 teeth

mt 10  20 mT 10  40
r   100mm R   200mm
2 2 2 2
ra  r  Add.  100  10  110mm RA  R  Add.  200  10  210mm
Pathof approach  R A
2
 R cosø   Rsinø
2

 
  2102   200cos20 
2
 200sin20 
 
 25.29mm
To avoid interference,
Maxlengthofpathof approach  rSin
 100  Sin20
 34.20mm 25.29mm
Therefore, interference will not occur.

Ex. 7.11 Two 20° involute spur gears have a module of 10 mm. The addendum is one module. The
larger gear has 50 teeth and the pinion has l3 teeth. Does interference occur? If it occurs,
to what value should the pressure angle change to eliminate interference?
Ø = 20°
M = 10 mm
Addendum = 1 module = 10 mm
T = 50 and t = 13
To be Calculated: Interference or not?
mt 10  13 mT 10  50
r   65mm R   250mm
2 2 2 2
ra  r  Add.  65  10  75mm RA  R  Add.  250  10  260mm
RCos   RSin  rSin 

2
Ramax 
250Cos20   250Sin20 
2
  65Sin20
 258.45mm
Here actual addendum radius Ra (260 mm) > Ra max value
So interference will occur.
The new value of ø can be found by comparing
Ra max  Ra
Ra  Ra max
RCos   RSin  rSin 
2
Ra 
250Cos   250Sin  65Sin 

2 2
260 
2602   250Cos    250Sin  65Sin 

2 2
Cos2  0.861
  21.88
Note: If pressure angle is increased to 21.88° interference can be avoided.
Ex. 7.12 The following data related to meshing involute gears:
No. of teeth on gear wheel = 60
Pressure angle = 20°
Gear ratio = 1.5
Speed of gear wheel = 100 rpm
Module = 8 mm
The addendum on each wheel is such that the path of approach and path of recess on
each side are 40 % of the maximum possible length each. Determine the addendum for
the pinion and the gear and the length of the arc of contact.
T = 60
Ø = 20°
G = 1.5
Ng = 100 rpm
m = 8 mm
To be Calculated:
Addendum for gear and pinion
Let pinion is the driver.
Max. Possible length of the path of approach  rsin 
 The actual length of the path of approach  0.4 rsin  (Given in data)
Same way, the actual length of the path of the recess  0.4 Rsin  (Given in data)
 0.4 r sin   R A
2
2

 0.4  160sin20  R A
2
 240cos20   240sin20
2

Ra  248.33 mm
 Addendum of wheel  248.3  240  8.3mm

Also,
0.4 Rsin   rA2  rcosø   rsinø
2
 0.4  240  sin20  rA2  160cos20   160sin20

2
ra  173.98  174 mm

 Addendum of pinion  174  160  14 mm
Pathof contact
Length of Arcof contact 
cos

rsin   Rsin    0.4
cos 

160  240   sin20  0.4
cos20
 58.2 mm
Ex. 7.13 A pinion of 20 ° involute teeth rotating at 274 rpm meshes with gear and provides a gear
ratio of 1.8. The no. of teeth on the pinion is 20 and the module is 8 mm. If interference
is just avoided, determine:
1. Addendum on wheel and pinion
2. Path of contact
3. Maximum velocity of sliding on both side of pitch point
Ø  20 1.Addndum on wheel and pinion  ?
m  8 mm 2.Path of contact  ?
Np  275 rpm 3.Max. velocity of sliding onboth side of pitchpoint  ?
T  36
t  20
Max. Addendum on wheel

 11  
 Aw max  R  1    2  sin2 ø  1
 G G  
 1  1  
 Aw max  144  1    2  sin2 20  1
 1.8  1.8  
 11.5 mm
Max. Addendum on pinion
 Ap max  r  1  G G  2  sin2 ø  1
 
 Ap max  80  1  1.8 1.8  2  sin 20  1
2
 
= 27.34 mm
Path of contact when interference is just avoided
 Max. path of approach  Max. path of recess
 rsin   Rsin 
 80sin20  144sin20
 27.36  49.25
 76.6 mm
The velocity of sliding on one side of the approach
 2 275 
 P   28.8 rad / sec 
  p  g  Path of approach 
60

 g 
28.8
 16 rad / sec 
 
 1.8  G 
  28.8  16   27.36
 1225.72 mm / sec
The velocity of sliding on side of the path of recess
  p  g Path of recess
 (28.8  16)  49.25
 2206 mm/ sec

Ex. 7.14 A pinion of 20 involute teeth and 125 mm pitch circle diameter drives a rack. The
addendum of both pinion and rack is 6.25 mm. What is the least pressure angle which
can be used to avoid interference? With this pressure angle, find the length of the arc of
contact and the minimum number of teeth in contact at a time.
T  20 1.Least pressure angle to avoid interference  ?
d  125mm 2. Length of arc of contact  ?
r  OP  62.5mm 3. Min. no. of teeth in contact  ?
Addendum for rack / pinion, LH  6.25mm

Least pressure angle to avoid interference
Let, ø = Least pressure angle to avoid interference
We know that for no interference, rack addendum,
From fig..... LH  PLsin 

 rsin  sin 
 rsin2 
LH 6.25
sin2   
r 62.5
  (18.4349)
Length of the arc of contact
Now, KL  OK2  OL2

 (OP 6.25)2  (rcos )2
 (62.5  6.25)2  (62.5  cos18.439 )2
 34.8 mm
KL 34.8
Length of Arc of Contact    36.68 mm
cos  cos18.439

Min. no. of teeth in contact 
pc

 m
36.68

19.64
 1.87
2
Ex. 7.15 In a spiral gear drive connecting two shafts, the approximate center distance is 400 mm
and the speed ratio = 3. The angle between the two shafts is 50° and the normal pitch is
18 mm. The spiral angles for the driving and driven wheels are equal. Find:
1. Number of teeth on each wheel,
2. Exact center distance,
3. The efficiency of the drive, if friction angle = 6°,
4. Maximum efficiency.
Solution: Given data:
T2
L  400 mm   50 G 3
T1
6 PN  18 mm
1. No. of teeth on a wheel:
PN  T1  1 G 
L   
2  cos 1 cos 2 
PN  T1 1  G
 400  
2 cos 1
 1   2 
 
18  T1 1  3    1   2 
 400  
2 cos25   50  21 
 
 1  25 
 T1  31.64 32
 T2  3T1  96
2. Exact center distance (L):
PN  T1  1 G 
L   
2  cos 1 cos 2 
PN  T1  1  G 
   ( 1   2 )
2  cos 1 
18  32  1  3 

2  cos25 
 404.600 mm
3. The efficiency of drive:
cos  2     cos 1

cos  1     cos 2
cos  1   
 ( 1   2 )
cos  1   
cos  25  6 

cos  25  6 
 90.655 %
4. Maximum efficiency:
cos       1
max 
cos       1
cos  50  6   1

cos  50  6   1
 90.685 %

Ex. 7.16 A drive on a machine tool is to be made by two spiral gear wheels, the spirals of which
are of the same hand and has a normal pitch of 12.5 mm. The wheels are of equal
diameter and the center distance between the axes of the shafts is approximately 134
mm. The angle between the shafts is 80° and the speed ratio 1.25. Determine:
1. the spiral angle of each wheel,
2. The number of teeth on each wheel,
3. The efficiency of the drive, if the friction angle is 6°, and
4. The maximum efficiency.
Solution: Given data:
PN  12.5mm
L  134 mm
G  1.25
  80
1. The spiral angle of each wheel
We know that........
d2 T2Cos1
 
d1 T1Cos2
 T1Cos2  T2Cos1 ( d1  d2 )
T
Cos1  1.25Cos2 ( 1  G  1.25)
T2
Cos1  1.25 Cos(  1 ) ( 1  2  )
Cos1  1.25 Cos(80  1 )
Cos1  1.25  Cos80  Cos1  Sin80  Sin1 
 Cos(A  B)  CosA  CosB  SinA  SinB 
𝐵𝑦 𝑠𝑜𝑙𝑣𝑖𝑛𝑔,
tan𝛼1 = 0.636
∴ 𝛼1 = 32.46∘
𝑎𝑛𝑑 𝛼2 = 80∘ − 32.46∘ = 47.54∘
2. The efficiency of drive:
cos  2     cos 1

cos  1     cos 2
cos  47.24  6   cos32.46

cos  32.46  6   cos47.24
 83 %

3. No. of teeth on the wheel:
d1  d2
L
2
2d
134  1 ( d1  d2 )
2
d1  134 mm
d1 p T
Let pc1   d1  c1 1
T1 
P T
d1  N  1
cos 1 
d  cos 1  
 T1  1
PN
134  cos32.24  
 T1 
12.5
 T1  28.4 30 nos.
T1 T 30
Now, G   1.25  T2  1 
T2 G 1.25
T2  24 nos.
4. Maximum efficiency:
cos       1
max 
cos       1
cos  80  6   1

cos  80  6   1
 83.8 %
Ex. 7.17 The addendum of the teeth is 0.84 module and the power component is 0.95 times the
normal thrust. Find the minimum no. of teeth on the gear wheel and the arc of contact (in
terms of the module) to avoid the interference in the following cases:
I. The gear ratio is unity

II. The gear ratio is 3
III. Pinion gear with a rack
Solution: Here A w  0.84

Cos  0.95    18.19
sin   0.3122

I. Gear ratio is unity
Let, min. no of teeth on gear wheel T
2 Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
2 Aw  G

 G2  1  2G sin2 ø  G
 
2  0.84  1

 12  1  2  (0.3123)2  1
 
 12.73
 T  13 teeth
 t  13 teeth
Length of the arc of contact:
L.P.C   RA2  Rcos ø   Rsin ø 

2
2

 m  t m  13 
 r  2  2  6.5m 
2  rA2  rcos ø   rsin ø
2
 
 rA  r  addendum 
  6.5m  0.84m


 
  7.34m 
 2m  (7.34)  6.5 0.95  (6.5 0.3123)
2 2
 3.876m
3.876m 3.876m
L.A.C  
cos ø 0.95
L.A.C  4.08m
II. Gear ratio G = 3
Let, min. no of teeth on gear wheel T
2 Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
2 Aw  G

 G2  1  2G sin2 ø  G
 

2  0.84  3

 32  1  2  3  (0.3123)2  3
 
 45.11
 T  45 teeth
 t  15 teeth
L.P.C  R A
2
2
2
 (1)
 m  t m  15 
 r  2  2  7.5m 
 
  7.5m  0.84m 
 
  8.34m 
 mT m  45 
R    22.5m 
 2 2 
 RA  R  addendum 
 
  22.5m  0.84m 
  23.34m 
 
putting all values in equation (1)
  (23.34m)  22.5m 0.95  22.5m 0.3122   (8.34m)  7.5m  0.95  7.5m 0.3122
2 2 2 2
 4.343m
4.343m 3.876m
L.A.C  
cos ø 0.95
L.A.C  4.57m
III. Pinion gear with a rack
Min. no. of teeth on pinion t
2 AR 2  0.84
t 
sin  (0.3123)2
2
 t  17.23
 t  18

L.P.C R A
2
2
 rA 2  rcos ø   rsin ø
2

 2 r  rcos ø   rsin ø 
2 2
A ( assume rack andpinion same dimension)
 mt 18m 
 r  2  2  9m 
2  (9.84)  9m 0.95  9m 0.3123
2 2 
  9m  0.84m 

 
  9.84m 
 4.12m
4.12m 4.12m
L.A.C  
cos ø 0.95
L.A.C  4.337m
Ex. 7.18 The gearing of a machine tool is shown in the figure. The motor shaft is connected to
gear A and rotates at 975 RPM. The gear wheels B, C, D, and E are fixed to parallel shafts
rotating together. The final gear F is fixed on the output shaft. What is the speed of gear
F? The number of teeth on each gear is as given below:
Gear A B C D E F
No. of teeth 20 50 25 75 26 65
TA  20 NF  ?
TB  50
TC  25
TD  75
TE  26
TF  65
NA  975 rpm
NF TA TC TE
  
NA TB TD TF
NF 20 20 26
   
975 50 75 65
NF  52 rpm
Ex. 7.19 In an epicyclic gear train, an arm carries two gears A and B having 36 and 45 teeth
respectively. If the arm rotates at 150 rpm in the anticlockwise direction about the center
of the gear A which is fixed, determine the speed of gear B. If the gear A instead of being
fixed makes 300 rpm in the clockwise direction, what will be the speed of gear B?
TA  36 Gear A fixed  NB  ?
TB  45 NA  300(Clockwise)  NB  ?
NC  150(Anticlockwise)
Sr. Revolution of element

Condition of motion
No. Arm C Gear A Gear B
Arm fixe, gear A rotates +1 TA

1 0 +1 
revolution(anticlockwise) TB
Arm fixed gear A rotates TA

2 0 x x
through + x revolutions TB
Add + y revolutions to all

3 y y y
elements
TA
4 Total motion y x y y- x
TB
1. Speed of gear B (NB) when gear A is fixed
Here, gear A fixed

xy0
 x  150  0
 x  150

TA
Speed of gear B (NB)  y  x
TB
36
 y  (150)
45
 270rpm (Anticlockwise)
2. Speed of gear B (NB) when gear NA = -300 (Clockwise)
Here given
x  y  300
 x  150  300
 x  450 rpm
Speed of gear B (NB)
TA
 yx
TB
36
 150  (450)
45
 510 rpm(Anti clockwise)
Ex. 7.20 In a reverted epicyclic gear train, the arm A carries two gears B and C and a compound
gear D - E. The gear B meshes with gear E and the gear C meshes with gear D. The number
of teeth on gears B, C and D are 75, 30 and 90 respectively. Find the speed and direction
of gear C when gear B is fixed and the arm A makes 100 rpm clockwise.
TB  75 GearBfixed  NC  ?
TC  30 NA  100  NC  ?
TD  90
NA  100(Clockwise)

Let dC  dD  dB  dE (rC  rD  rB  rE )
 TC  TD  TB  TE
30  90  75  TE
 TE  45

Condition of motion
No. Arm C Gear A Gear B Gear C
Arm fixe, gear A rotates +1 TE TD

1 0 +1  
revolution(anticlockwise) TB TC
Arm fixed gear A rotates x

TE
x
TD
2 0 x
through + x revolutions TB TC

3 y y y y
elements
TE TD
4 Total motion y x y yx yx
TB TC
TE
GearBis fixed  y  x 0
TB
45
 100  x  0
75
 x  166.67
TD
Speed of gear C (NC )  y  x
TC
90
 100  (166.67) 
30
 400 rpm(Anti clockwise)

Condition of motion
Arm fixe, gear A rotates
TB TB TD
1 +1 0 +1   
TE TE TC
revolution(anticlockwise)
Arm fixed gear A rotates TB

x
TB TD

2 0 x x
through + x revolutions TE TE TC

3 y y y y
elements
TB TB TD
4 Total motion y x y yx yx 
TE TE TC

From fig (rC  rD  rB  rE )
 TC  TD  TB  TE
 TE  90  30  75
 TE  45
When gear B is fixed

x  y  0
 x  (100)  0
 x  100
TB TD
Now NC  y  x 
TE TC
75 90
 100  100  
45 30
NC  400 rpm (Anticlockwise)
Ex. 7.21 An epicyclic gear consists of three gears A, B and C as shown in the figure. 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 center of A at 18 RPM. If the
gear A is fixed, determine the speed of gears B and C.
TB  72 (Internal) Gear A fixed  NB  ?

TC  32 (External)  NC  ?
ArmEF  18rpm
From the geometry of the figure,
rA  rC  2rB
 TA  TC  2TB
 TB  20

Condition of motion
TC TC TB T
1 +1 revolution 0 +1     C
TB TB TA TA
(anticlockwise)
Arm fixed gear A rotates TC TC

2 0 +x x x
through + x revolutions TB TA

3 +y +y +y +y
elements
TC TC
4 Total motion y x+y yx yx
TB TA
1. Speed of gear C (Nc)
TC
Gear Ais fixed  y  x 0
TA
32
 18  x  0
72
 x  40.5
Speed of gear C (NC )  x  y

 40.5  18
 58.5rpm(inthedirectionof arm)
2. Speed of gear B (NB)
TC
Speedof gearB  y  x
TB
32
 18  40.5 
20
 46.8 rpm
 46.8 rpm (intheopposite direction of arm)
Ex. 7.22 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 rpm,
find the speed of shaft B.

TC  50 No.of teethon internal gear  ?

TD  20 Speed of shaft B  ?
TE  35
NC  110 (Rotationof shaft)
Revolution of element
Sr.
Condition of motion Gear C Compound
No. Arm C Gear G
(Shaft A) Gear (D-E)

TC TC TE
1 +1 0 +1   
TD TD TG
Arm fixed gear A rotates x

TC
x
TC TE

2 0 +x
through + x revolutions TD TD TG

3 +y +y +y +y
elements
TC TC TE
4 Total motion y x+y yx yx 
TD TD TG
dG dC dD dE
  
2 2 2 2
dG  dC  dD  dE
 TG  TC  TD  TE
 TG  50  20  35
 TG  105
Speed of shaft B
Here given gear G is fixed
TC TE
y  x  0
TD TG
50 35
y  x  0
20 105
5
y  x   0 (1)
6
Also given gear C is rigidly mounted on shaft A
x  y  110 (2)
Solving Eq. (1) & (2)
x  60
y  50
Speed of shaft B  Speed of arm   y  50 rpm
Ex. 7.23 In an epicyclic gear train, as shown in the figure, the number of teeth on wheels A, B and
C are 48, 24 and 50 respectively. If the arm rotates at 400 rpm, clockwise,
Find:
1. Speed of wheel C when A is fixed, and
2. Speed of wheel A when C is fixed

TA  48 Gear A fixed  NC  ?
TB  24 GearCfixed  NA  ?
TC  50 y  400 rpm (Arm rotationclockwise)

Condition of motion
TA  TA   TB  TA
1 +1 0 +1        
TB  TB   TC  TC
Arm fixed gear A rotates TA TA

2 0 x x x
through + x revolutions TB TC

3 y y y y
elements
TA TA
4 Total motion y x y yx yx
TB TC
1. Speed of wheel C when A is fixed
When A is fixed
xy0
 x  400  0
x0
TA
NC  y  x
TC
48
 400  400 
50
 16 rpm
NC  16 rpm (Clockwise direction)
2. Speed wheel A when C is fixed
When C is fixed
NC  0
T
y  x A  0
TC
48
400  x  0
50
 x  416.67
NA  x  y
 416.67  400
NA  16.67 (Anticlockwise)
Ex. 7.24 An epicyclic gear train, as shown in the figure, has a sun wheel S of 30 teeth and two
planet wheels P-P of 50 teeth. The planet wheels mesh with the internal teeth of a fixed
annulus A. The driving shaft carrying the sun wheel transmits 4 kW at 300 RPM. The
driven shaft is connected to an arm which carries the planet wheels. Determine the speed
of the driven shaft and the torque transmitted, if the overall efficiency is 95%.

TS  30 TP  50 TA  130
NS  300 rpm P  4 KW
rA  2rP  rS
 TA  2TP  TS
 2  50  30
 130
Sr.
Condition of motion
No.
Arm C Gear A Gear B Gear C

TS  TS   TP  TS
1 +1 0 +1       
TP  TP   TA  TA
Arm fixed gear A rotates TS TS

2 0 x x x
through + x revolutions TP TA

3 y y y y
elements
TS TS
4 Total motion y x y yx yx
TP TA
Here,
NS  300rpm
 x  y  300 (1)

Also, Annular gear A is fixed
TS
y  x 0
TA
30
y  x  0
130
 y  0.23x (2)
Solving equation eq. (1) & (2)
x  243.75
y  56.25
Speed of Arm = Speed of driven shaft = y = 56.25 rpm
Here, P = 4 KW &   95%
Pout
 
Pin
Pout   Pin
95
 4
100
 3.8 KW
Also,
2NT
Pout 
60
2 56.30T
3.8 103 
60
 T  644.5 N  m
Ex. 7.25 An epicyclic gear train is shown In figure. Find out the rpm of pinion D if arm A rotates at
60 rpm in the anticlockwise direction.

TD  40 ND  ?
TC  60
TB  120
NA  60 rpm (Anticlockwise)

Condition of motion
No. Arm C Gear B Gear C Gear D
TB TB TC T
1 +1 0 +1    B
TC TC TD TD
Arm fixed gear A rotates TB TB

2 0 x x x
through + x revolutions TC TD

3 y y y y
elements
TB TB
4 Total motion y x y yx yx
TC TD
From fig. Gear B is fixed

x  y  0
 x  60  0 ( rpmof armA  60  y)
 x   60
Now the motion of gear D
TB
yx
TD
120
 60  60 
40
 120 rpm
D rotates 120 rpm in the clockwise direction.
Ex. 7.26 An epicyclic gear train for an electric motor is shown in the figure. The wheel S has 15
teeth and is fixed to the motor shaft rotating at 1450 RPM. The planet P has 45 teeth,
gears with fixed annulus A and rotates on a spindle carried by an arm that is fixed to the
output shaft. The planet P also gears with the sun wheel S. Find the speed of the output
shaft. If the motor is transmitting 1.5 kW, find the torque required to fix the annulus A.

TS  15 Speedof outputshaft  ?
TP  45 Torque  ?
From figure,
rA  rs  2rP
 TA  TS  2TP
 TA  105

Condition of motion
No. Spindle Gear S Gear P Gear A
Sector/Spindle fixed,
gear S rotates +1 TS TS TP T
1 0 +1     S
revolution TP TP TA TA
(anticlockwise)
Spindle fixed gear S
TS TS
2 rotates through + x 0 x x x
TP TA
revolutions
Add + y revolutions to
3 y y y y
all elements
TS TS
4 Total motion y x y yx yx
TP TA
Motor shaft is fixed with gear S
 x  y  1450 (1)
And Annular A is fixed
TS
y  x 0
TA
15
y  x 0
105
15
y  x (2)
105
By solving equation (1) & (2)
x  1268.76
y  181.25
Speed of output shaft y = 181.25 rpm
 Torque on sun wheel (S) (input torque)
2NTi
P
60
P  60
 Ti 
2N
 2  103  60  2 
   1.35HP  1KW  2 HP  KW 
 1.35  2 1450  1.35 
 9.75N  m

 Torque on output shaft (with 100% mechanical efficiency)
P  60
 To 
2N
 2  103  60
 
 1.35  2 181.25
 78.05 N  m
 Fixing torque
 To  Ti
 78.05  9.75
 68.3N  m
Ex. 7.27 If wheel D of gear train as shown in the figure, is fixed and the arm A makes 140
revolutions in a clockwise direction. Find the speed and direction of rotation of B & E. C
is a compound wheel.
TB  30 TC  35 TD  19 TE  30

Condition of motion
No. Spindle Gear S Gear P Gear A
20  20   35   19 
1 +1 0 +1        
15  15   19   30 
Arm fixed gear A rotates

2 0 x 1.33x 1.555x
through + x revolutions
3 y y y y
elements
4 Total motion y x y y  1.33x y 1.555x

 When gear D is fixed
y  2.456x  0
140  2.456x  0 ( y  140rpm given)
x  57
 Speed of gear B
NB  x  y
 57  140
 83rpm(Clockwise)
 Speed of gear E
NE  y  1.555x
 140  1.555(57)
 228.63rpm (Clockwise)
Ex. 7.28 The epicyclic train as shown in the figure is composed of a fixed annular wheel A having
150 teeth. Meshing with A is a wheel b which drives wheel D through an idle wheel C, D
being concentric with A. Wheel B and C is carried on an arm which revolves clockwise at
100 rpm about the axis of A or D. If the wheels B and D are having 25 teeth and 40 teeth
respectively, Find the no. of teeth on C and speed and sense of rotation of C.
Solution:
From the geometry of figure,
rA  2rB  2rC  rD
 TA  2TB  2TC  TD
150  50  2TC  40
 TC  30

Condition of motion
No. Arm Gear D Gear C Gear B Gear A
Arm fixe, gear D

TD TD
1 rotates +1 revolution 0 +1   TD
TC TB 
(anticlockwise) TA
Arm fixed gear D

TD TD TD
2 rotates through + x 0 x x x x
TC TB TA
revolutions
Add + y revolutions
3 y y y y y
to all elements
TD TD TD
4 Total motion y x y yx yx yx
TC TB TA

Now
NA  0
TD
y  x 0
TA
40
100  x  0
150
 x  375
Let
TD
NC  y  x
TC
40
 100  375 
30
 600rpm
Ex. 7.29 The figure 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 from the rear axles to which the road wheels are attached. If the propeller shaft rotates
at 1000 rpm and the road wheel attached to axle Q has a speed of 210 rpm. while taking
a turn, find the speed of the road wheel attached to axle P.

TA  12
TB  60
NQ  ND  210rpm
NA  1000rpm
Let,
NA  TA  NB TB
T
NB  NA  A
TB
12
 1000 
60
 200rpm

Condition of motion
No. Gear B Gear C Gear E Gear D
Gear B is fixed, gear C
TC
1 rotates +1 0 +1  -1
TE
Gear B is fixed gear C
TC
2 rotates through + x 0 x x x
TE
revolutions
3 y y y y
elements
TC
4 Total motion y x y yx yx
TE
Let here speed of gear B is 200 rpm

NB  200  y
From table
ND  y  x  210
 x  y  210
 x  200  210
 x  10rpm
Let the speed of road wheel attached to the axle P = Speed of gear C
xy
 10  200
 180rpm
Ex. 7.30 Two bevel gears A and B (having 40 teeth and 30 teeth) are rigidly mounted on two co-
axial shafts X and Y. A bevel gear C (having 50 teeth) meshes with A and B and rotates
freely on one end of an arm. At the other end of the arm is welded a sleeve and the sleeve
is riding freely loose on the axes of the shafts X and Y. Sketch the arrangement. If the
shaft X rotates at 100 RPM. clockwise and arm rotates at 100 RPM. anticlockwise, find
the speed of shaft Y.

TA  40 TC  50 TB  30
NX  NA  100rpm(Clockwise)
Speedof arm  100rpm

Condition of motion
No. Arm Gear A Gear C Gear B
Arm fixe, gear A rotates +1 TA TA

1 0 +1  
revolution(anticlockwise) TC TB
Arm fixed gear A rotates TA TA

2 0 x x x
through + x revolutions TC TB

3 y y y y
elements
TA TA
4 Total motion y x y yx yx
TC TB
Here speed of arm = y =+100 rpm (given)
Also given NA  NX  100rpm

NA  x  y
100  x  100
x  200
Speed of shaft Y  NB
TA
 yx
TB
40
 100  200 
30
 366.7rpm (Anticlockwise)
Ex. 7.31 An epicyclic train of gears is arranged as shown in the figure. 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 makes 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 90 respectively.

TA  40
TD  90
First of all, let us find the number of teeth on gear B and C (i.e. T B and Tc). Let dA, dB, dC, dD be the pitch
circle diameter of gears A, B, C, and D respectively. Therefore from the geometry of fig,
dA + dB + dC = dD or dA + 2 dB = dD ...( dB = dC )
Since the number of teeth is proportional to their pitch circle diameters, therefore,
TA + 2 TB = TD or 40 + 2 TB = 90
 TB = 25, and TC = 25 ...( TB = TC )
Revolutions of elements
Sr.
Conditions of motion Compound
No. Arm Gear A Gear D
Gear B-C
Arm fixe, gear A rotates TA  TA   TB  TA

1 0 1        
-1 revolution(clockwise) TB  TB   TD  TD
Arm fixed gear A rotates x

TA
x
TA
2 0 x
through - x revolutions TB TD
Add - y revolutions to all y y y y

3
elements
TA TA
4 Total motion y x  y x y x y
TB TC
1. Speed of arm when A makes 1 revolution clockwise and D makes half revolution
anticlockwise
Since the gear A makes 1 revolution clockwise, therefore from the fourth row of the table,
x  y  1 or x  y 1 ...(1)
Also, the gear D makes half revolution anticlockwise, therefore
TA 1
x y
TD 2
40 1
x   y 
90 2
 40x  90y  45
 x  2.25y  1.125 ...(2)
From equations (1) and (2),

x  1.04 and y  0.04
Speed of arm  y  (0.04)  0.04
 0.04 revolution(Anticlockwise)
2. Speed of arm when A makes 1 revolution clockwise and D is stationary

Since the gear A makes 1 revolution clockwise, therefore from the fourth row of the table,
x  y  1
x  y  1 ...(3)
Also, the gear D is stationary, therefore
TA
x y0
TD
40
x   y  0
90
 40x  90y  0
 x  2.25y  0 ...(4)

Speedof arm  y  0.308
Speedof arm  0.308revolution (Clockwise)
Ex. 7.32 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.
TC = 28 ; TD = 26 ; TE = TF = 18
1. Sketch the arrangement
The arrangement is shown in the figure.
2. Number of teeth on wheels A and B

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.
dA = dC + 2 dE
And dB = dD + 2 dF

Since the number of teeth is proportional to their pitch circle diameters, for the same module,
therefore
TA = TC + 2 TE = 28 + 2 = 64
And TB = TD + 2 TF = 26 + 2 = 62
3. Speed of wheel B when arm G makes 100 r.p.m. clockwise and wheel A is fixed
First of all, the table of motions is drawn as given below:
Sr. Conditions of
Arm Wheel Wheel Compound
No motion Wheel F Wheel B
G A E wheel C-D
Arm fixe, A TA TE TA TD TF
rotates     
TA TE TC TA TD TC TF TB
1 0 1   
+1 revolution TE TA TC TF TA TD
  
(Anti clockwise) TC TC TB
Arm fixed A
TA TA TA TD TA TD
2 rotates through + 0 x x x x  x 
TE TC TC TF TC TB
x revolutions
Add +y
3 revolutions to all y y y y y y
elements
4 Total motion y x y TA TA TA TD TA TD
x y yx y  x  y  x 
TE TC TC TF TC TB
Since the arm G makes 100 r.p.m. clockwise, therefore from the fourth row of the table
y =  100
Also, wheel A is fixed, therefore from the fourth row of the table,
x+y=0 or x = -y=100
TA TD
Speedof wheel B  y  x  
TC TB
64 26
 -100  100  
28 62
 -100  95.8 r.p.m.  - 4.2r.p.m
Speedof wheel B  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
Since the arm G makes 100 r.p.m. clockwise, therefore from the fourth row of the table
y  100 ...(3)
Also, wheel A makes 10 r.p.m. counter-clockwise, therefore from the fourth row of the table,

x  y  10
 x  10  y
 x  10  100
 x  110 ...(4)
TA TD
 Speed of wheel B   y  x  
TC TB
64 26
 100  110  
28 62
 100  105.4 r.p.m
 5.4 r.p.m
 Speed of wheel B  5.4r.p.m (Anticlockwise)
Ex. 7.33 The figure shows diagrammatically a compound epicyclic gear train. Wheels A, D and E
are free to rotate independently on spindle O, while B and C are compound and rotate
together on spindle P, on the end of arm OP. All the teeth on different wheels have the
same module. A has 12 teeth, B has 30 teeth and C has 14 teeth cut externally. Find the
number of teeth on wheels D and E which are cut internally. If the wheel A is driven
clockwise at 1 r.p.s. while D is driven counter-clockwise at 5 r.p.s., determine the
magnitude and direction of the angular velocities of arm OP and wheel E.
Solution: Given: TA  12; TB  30; TC  14; NA  1 r.p.s.; ND  5r.p.s

Number of teeth on wheels D and E
Let TD and TE as the number of teeth on wheels D and E respectively. Let dA, dB, dC, dD, and dE be the pitch
circle diameters of wheels A, B, C, D, and E respectively. From the geometry of the figure,
dE  dA  2dB and dD = dE  (dB  dC )
Since the number of teeth is proportional to their pitch circle diameters for the same module, therefore
TE  TA  2TB TD  TE  (TB  TC )
 TE  12  2  30  TD  72  (30  14)
 TE  72  TD  56

Magnitude and direction of angular velocities of arm OP and wheel
The table of motions is drawn as follows:
Sr.
Condition of motion Wheel Compound
No. Arm Wheel D Wheel E
A wheel B-C
Arm fixe, gear A rotates TA TA TC TA TB T

1 0 -1       A
-1 revolution(clockwise) TB TB TD TB TE TE
Arm fixed gear A rotates TA TA TC TA

2 0 x x x  x
through - x revolutions TB TB TD TE
Add - y revolutions to all y y y y y

3
elements
TA TA TC TA
4 Total motion y x  y x y x  y x y
TB TB TD TE
Since the wheel A makes 1 r.p.s. clockwise, therefore from the fourth row of the table,
 x  y  1
x  y  1 (1)
Also, the wheel D makes 5 r.p.s. counter-clockwise, therefore
TA TC
x  y5
TB TD
T T
x A  C  y  5
TB TD
12 14
x   y  5
30 56
 0.1x  y  5 (2)
x  5.45 and y  -4.45
Angular velocity of arm OP
 y  (4.45)  4.45 r.p.s
 4.45  2  27.964rad / sec (Anti clockwise)
And the angular velocity of wheel E

TA
x y
TE
12
 5.45   (4.45)
72
 5.36 r.p.s
 5.36  2
 33.68 rad / sec (Anti clockwise)

Ex. 7.34 The figure shows an epicyclic gear train known as Ferguson’s paradox. Gear A is fixed to
the frame and is, therefore, stationary. The arm B and gears C and D are free to rotate on
the shaft S. Gears A, C and D have 100, 101 and 99 teeth respectively. The planet gear
has 20 teeth. The pitch circle diameters of all are the same so that the planet gear P
meshes with all of them. Determine the revolutions of gears C and D for one revolution of
the arm B.
Solution: Given : TA = 100 ; TC = 101 ; TD = 99 ;TP = 20

The table of motions is given below:
Sr.
Condition of motion Arm Gear
No. Gear C Gear D
B A
Arm B fixe, gear A rotates +1 TA TA TC TA
1 0 +1    
revolution(anticlockwise) TC TC TD TD
Arm B fixed gear A rotates through + x TA TA
2 0 x x x
revolutions TC TD
3 Add + y revolutions to all elements y y y y
TA TA
4 Total motion y x y yx yx
TC TD
The arm B makes one revolution, therefore

y=1
Since the gear A is fixed, therefore from the fourth row of the table,
x+y=0
x  y  1
Let NC and ND = Revolutions of gears C and D respectively.

From the fourth row of the table, the revolutions of gear C,
TA
NC  y  x
TC
100
1  1 
101
1
NC  
101
And the revolutions of gear D,
TA 100
ND  y  x  1
TD 99
1
 ND  
99
From above we see that for one revolution of the arm B, the gear C rotates through 1/101 Revolution in
the same direction and the gear D rotates through 1/99 revolutions in the opposite direction.
Ex. 7.35 The figure shows an epicyclic gear train. Pinion A has 15 teeth and is rigidly fixed to the
motor shaft. The wheel B has 20 teeth and gears with A and also with the annular fixed
wheel E. Pinion C has 15 teeth and is integral with B (B, C being a compound gear wheel).
Gear C meshes with annular wheel D, which is keyed to the machine shaft. The arm
rotates about the same shaft on which A is fixed and carries the compound wheel B, C. If
the motor runs at 1000 r.p.m., find the speed of the machine shaft. Find the torque
exerted on the machine shaft, if the motor develops a torque of 100 N-m.
Solution: Given : TA = 15 ; TB = 20 ; TC = 15 ; NA = 1000 r.p.m.;

Torque developed by motor (or pinion A) = 100 N-m
1. Speed of the machine shaft
The table of motions is given below:
Sr.
Condition of motion Pinion Compound
No. Arm Wheel D Wheel E
A wheel D-C
TA TA TC TA TB T
1 +1 0 +1       A
TB TB TD TB TE TE
Arm fixed gear A rotates TA TA TC TA

2 0 x x x  x
through + x revolutions TB TB TD TE

3 y y y y y
elements
TA TA TC TA
4 Total motion y x y yx yx  yx
TB TB TD TE

First of all, let us find the number of teeth on wheels D and E. Let T D and TE as the number of teeth on
wheels D and E respectively. Let dA, dB, dC, dD, and dE be the pitch circle diameters of wheels A, B, C, D,
and E respectively. From the geometry of the figure,
dE = dA + 2 dB and dD = dE -(dB -dC )
Since the number of teeth is proportional to their pitch circle diameters, therefore,
TE = TA + 2 TB = 15 + 2  20 = 55
TD = TE  (TB  TC )  55  (20  15)  50
We know that the speed of the motor or the speed of the pinion A is 1000 r.p.m.
Therefore
x + y = 1000 ...(1)
Also, the annular wheel E is fixed, therefore
TA
yx 0
TE
TA
y  x
TE
15
y  x
55
 y  0.273x ...(2)
x = 786 and y = 214
 Speedofmachineshaft  Speedof wheel D
T T
ND  y  x A  C
TB TD
15 15
 214  786  
20 50
  37.15 r.p.m.
ND  37.15 (Anticlockwise)
The torque exerted on the machine shaft

We know that
Torque developed by motor  Angular speed of motor
 Torque exerted on machine shaft  Angular speed of machine shaft
100  A  Torque exerted on machine shaft  D

 Torque exerted on machine shaft  100  A
D
N 1000
 100  A  100 
ND 37.5
 Torque exerted on machine shaft  2692 N  m

Ex. 7.36 An epicyclic gear train consists of a sun wheel S, a stationary internal gear E and three
identical planet wheels P carried on a star-shaped planet carrier C. The sizes of different
toothed wheels are such that the planet carrier C rotates at 1/5th of the speed of the sun
wheel S. The minimum number of teeth on any wheel is 16. The driving torque on the sun
wheel is 100 N-m. Determine 1. Number of teeth on different wheels of the train, and 2.
torque necessary to keep the internal gear stationary.
Solution: NS
Given NC 
5
1. Number of teeth on different wheels
The arrangement of the epicyclic gear train is shown in the figure. Let TS and TE as the number of teeth
on the sun wheel S and the internal gear E respectively. The table of motions is given below:
Sr.
Conditions of motion Plant carrier Sun wheel Planet
No. Internal Gear E
C S Wheel P
Planet carrier C fixed,
sun wheel S rotates 
TS

TS TP T
  S
1 0 +1
through + 1 revolution TP TP TE TE
(anticlockwise)
Planet carrier C fixed,
TS TS
2 sun wheel S rotates 0 x x x
TP TE
through + x revolutions
Add + y revolutions to
3 y y y y
all elements
TS TS
4 Total motion y x y yx yx
TP TE
We know that when the sun wheel S makes 5 revolutions, the planet carrier C makes 1 revolution.
Therefore from the fourth row of the table,
y  1, and x  y  5
x  4

Since the gear E is stationary, therefore from the fourth row of the table,
TS
yx 0
TE
TS
1  4 0
TE
 TE  4TS
Since the minimum number of teeth on any wheel is 16, therefore let us take the number of teeth on the
sun wheel,
TS  16
 TE  4  16  64
Let dS, dP, and dE be the pitch circle diameters of wheels S, P and E respectively. Now from the geometry
of Fig
dS + 2 dP = dE
Assuming the module of all the gears to be the same, the number of teeth is proportional to their pitch
circle diameters.
TS  2 TP  TE
16  2TP  64
 TP  24
2. Torque necessary to keep the internal gear stationary

We know that
Torque on S  Angular speed of S  Torque on C  Angular speed of C
100  S  Torque on C  C

 Torque on C  100  S
C
N
 100  S
NC
 100  5
 Torque on C  500 N  m
 Torque necessary to keep the internal gear stationary
 500  100
 400 N  m
References:
1. Theory of Machines, Rattan S S, Tata McGraw-Hill
2. Theory of Machines, Khurmi R. S., Gupta J. K., S. Chand Publication
3. Theory of machines and mechanisms, Ballaney P. L., Khanna Publishers


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Contents

7.1 Introduction ....................................................................................................................................... 7.2

Fig.7.1 – Friction Wheels

7.1.1 Advantages of gear Drive

7.1.2 Disadvantages of gear Drive

Dr. A. J. Makadia, Department of Mechanical Engineering

7.1.3.1 According to the position of axes of the shafts

Fig.7.2 – Spur Gear

 Spur rack and pinion

Fig.7.3 – Rack and Pinion

Dr. A. J. Makadia, Department of Mechanical Engineering

Fig.7.4 – Helical gear

Fig.7.5 – Herringbone gear

Dr. A. J. Makadia, Department of Mechanical Engineering

Fig.7.6 - Straight Bevel Gears

 Spiral Bevel Gears

Fig.7.7 – Spiral Bevel Gears

Dr. A. J. Makadia, Department of Mechanical Engineering

Fig.7.8 – Zero Bevel Gear

Fig.7.9 - Non-intersecting and non-parallel shaft

Dr. A. J. Makadia, Department of Mechanical Engineering

7.1.3.3 According to the position of teeth on the gear surface

7.2 Terms Used in Gears

Fig.7.10 - Terms used in gears

Dr. A. J. Makadia, Department of Mechanical Engineering

Dedendum circle diameter  d  2  1.157m

Clearance  1.157m  m  0.157m

Dr. A. J. Makadia, Department of Mechanical Engineering

Fig.7.11 – Law of gearing

(ω1 × 𝑂1 𝐶) cos 𝛼 = (ω2 × 𝑂2 𝐶) cos 𝜃 (∵ 𝑉 = 𝑟 𝜔) Eq. (7.1)

Dr. A. J. Makadia, Department of Mechanical Engineering

From a similar triangle  O1 AP &  O2 BP

7.2.2 Standard Tooth Profiles or Systems

Dr. A. J. Makadia, Department of Mechanical Engineering

c) 20 full depth involute system:

Fig.7.14 - 20 full depth involute system

d) 20 stub involute system:

Fig.7.15 - 20 stub involute system

Dr. A. J. Makadia, Department of Mechanical Engineering

7.3 Length of Path of Contact And Length of Arc of Contact

7.3.1 Length of Path of Contact

Fig.7.16 - Length of Path of Contact

Dr. A. J. Makadia, Department of Mechanical Engineering

  O2K2  O2N2  PN    O1L2  O1M2  MP 

Length of the arc of contact GPH   GP  PH 

 Arc of approach  Arc of recess

7.3.3 Contact Ratio (or Number of Pairs of Teeth in Contact)

Length of arc of contact

Dr. A. J. Makadia, Department of Mechanical Engineering

7.4 Interference in Involute Gears

Fig.7.17 - Interference in involute gears

Dr. A. J. Makadia, Department of Mechanical Engineering

The maximum length of the arc of contact 

7.4.2 Minimum Number of Teeth on the Pinion in Order to Avoid Interference

O1N 2  O1P 2  PN2  2OP  PNcos O1PN 

O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

O1N2  r2  R2 sin2 ø  2rRsin2 ø

Addendum of the pinion  O1N– O1P

Dr. A. J. Makadia, Department of Mechanical Engineering