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Design of Gears
Introduction
Gear
drive is also provided, when the distance between the Driver and the
Follower is very small
Friction Wheels
Motion
o
o
Design of Gears
Introduction
Friction Wheelscontd--
Friction Wheel with the teeth cut on it is known as Gear or Toothed Wheel
Design of Gears
Introduction
In any pair of gears, smaller one is called Pinion and the larger one is called
Gear immaterial of which is driving the other
When Pinion is Driver, it results in step down drive in which the output speed
decreases and the torque increases
when
Design of Gears
Introduction
Advantages of Gear Drives
o Transmits exact velocity ratio, without slipping which is not possible in case
o
o
o
o high efficiency
o compact layout
Design of Gears
Classification of Gears
1. According to the position of axes of the shafts
Axes of the two shafts between which the motion is to be transmitted, may be
(a) Parallel
(b) Intersecting
(c) Non-intersecting and non-parallel
Design of Gears
Classification of Gears
1. According to the position of axes of the
shaftscontd-Helical Gears/Spur Gearing
Double Helical Gear balance out the end thrusts that are
induced in single helical gears when transmitting load
o
o
Design of Gears
Classification of Gears
1. According to the position of axes of the shaftscontd-Bevel Gears/Bevel Gearing
two non-parallel or
intersecting,
but
coplaner
shafts
connected by gears
Design of Gears
Classification of Gears
1. According to the position of axes of the shaftscontd-Bevel Gears/Bevel Gearingcontd--
Design of Gears
Classification of Gears
2. According to the Peripheral Velocity of the Gears
(a) Low Velocity
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Design of Gears
Classification of Gears
3. According to Type of Gearing
Internal Gearing
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o
o
o
o
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Design of Gears
Nomenclature
Pitch Circle: Theoretical circle upon which all calculations are usually based
Pitch Circle Diameter: diameter of the pitch circle
Size of the gear is usually specified by Pitch Circle Diameter
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Design of Gears
Nomenclature
Addendum:
Radial distance of a tooth from the pitch circle to the top of the
tooth
Dedendum: Radial distance of a tooth from the pitch circle to the bottom of the
tooth
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Design of Gears
Nomenclature
Addendum Circle: Circle drawn through the top of the teeth and is concentric
with the pitch circle
Dedendum
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Design of Gears
Nomenclature
Clearance: Radial distance from the top of the tooth to the bottom of the tooth,
in a meshing gear. A circle passing through the top of the meshing gear is
known as Clearance Circle
Total depth: It is the radial distance between the addendum and the dedendum
circle of a gear, i.e. sum of the addendum and dedendum
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Design of Gears
Working
Nomenclature
Tooth Thickness: Width of the tooth measured along the pitch circle
Tooth space / width of space: space between the two adjacent teeth measured
along the pitch circle
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Design of Gears
Nomenclature
Face of the tooth: Surface of the tooth above the pitch surface
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Design of Gears
Nomenclature
Flank of the tooth: It is the surface of the tooth below the pitch surface
Face Width: It is the width of the gear tooth measured parallel to its axis
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Design of Gears
Nomenclature
Circular Pitch (pc): distance, measured on the pitch circle, from a point on one
tooth to a corresponding point on an adjacent tooth
It is equal to the sum of the Tooth Thickness and the Width of Space
pc = D/T
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Design of Gears
Nomenclature
Diametral
Module (m): Ratio of the pitch circle diameter in millimeters to the number of
teeth
m=D/T
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Design of Gears
Nomenclature
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Design of Gears
Nomenclature
Actual Size of the Gear Tooth for Different Diametral Pitches
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Design of Gears
Nomenclature
Standard Diametral Pitches
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Design of Gears
Nomenclature
Fillet radius: Small radius that connects the profile of the tooth to the root circle
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Design of Gears
Condition for Constant Velocity Ratio of GearsLaw of Gearing
point
If
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Design of Gears
Condition for Constant Velocity Ratio of GearsLaw of Gearing
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Design of Gears
Condition for Constant Velocity Ratio of GearsLaw of Gearing
To
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Design of Gears
Gear Profiles
Profiles which satisfy the Law Of Gearing are called Conjugate Profiles, these
are:
(a) Involute
(b) cycloidal
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Design of Gears
Gear Profiles
Involute Gear Tooth Profile
Involute is the path generated by the end of a thread as it unwinds from a Reel
o
o
o
o
o
Involute gear
tooth profile
appearance after
generation
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Design of Gears
Gear Profiles
Involute Gear Tooth Profilecontd--
o
o
o
Involute gears are economical to make because the cutters used to make the gears are
straight
Variation in center distance does not affect the Velocity Ratio
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Design of Gears
Gear Profiles
Cycloidal Gear Tooth Profile
Cycloid
If
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Design of Gears
Gear Profiles
Cycloidal Gear Tooth ProfileContd--
Two generating circles roll on the pitch circle to trace the cycloidal tooth profile
o
o
Advantages
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Design of Gears
Gear Terminologies during meshing
Pitch Point: point of tangency of the pitch circles of a pair of mating gears
Common Tangent: The line tangent to the pitch circle at the pitch point
Line of action: A line normal to a pair of mating tooth profiles at their point of
contact.
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Design of Gears
Gear Terminologies during meshing
Pressure angle : Angle between the common normal at the point of tooth contact
and the common tangent to the pitch circles
o Standard values are 14.5, 20 and 25 degrees
o 14.5 were common as the cosine is larger for a smaller angle, providing more power
transmission and less pressure on the bearing
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Design of Gears
Gear Terminologies during meshing
Pressure angle contd--
o
o
All mating gears must be of the same pressure angle to mesh properly
20-degree tooth form has a greater factor of safety in strength, runs smoother, wears
longer, and is no more expensive to manufacture than the 14.5-degree tooth form
20-degree tooth is wider at the base and consequently is stronger than the 14.5-degree
tooth form
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Design of Gears
Example 7.1
A gear set consists of a 16 tooth pinion driving a 40 teeth gear. The diametral
pitch is 2. The addendum and addendum are 1/pd and 1.25/pd respectively.
Pressure angle is 20o.
(a) Compute
the circular pitch, the central distance and the radii of base
circles.
(a) In
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Design of Gears
Tooth Systems
Standard makes it easy for design, production, quality assurance, replacement etc
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Design of Gears
Tooth Systems
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Design of Gears
Contact Ratio
Tooth contact begins and ends at the intersections of the two addendum circles
with the pressure line
Tooth profiles drawn through these points intersect the pitch circle at A and B
o Distance AP is called the arc of approach qa
o Distance PB, the arc of recess qr
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Design of Gears
Contact Ratio
o qa +qr = qt = Arc of Action
If arc of action is exactly equal to the circular pitch, i.e, qt = p, one tooth and
its space will occupy the entire arc AB
when a tooth is just beginning contact at a, the previous tooth is simultaneously
ending its contact at b
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Design of Gears
Contact Ratio
If arc of action is greater than the circular pitch, but not very much greater, say,
qt = 1.2p
one pair of teeth is just entering contact at a, another pair, already in contact, will not
yet have reached b
Thus, for a short period of time, there will be two teeth in contact, one in the vicinity of
A and another near B
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Design of Gears
Contact Ratio
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Design of Gears
Design Considerations for a Gear Drive
gear teeth should have sufficient strength under static loading or dynamic loading
during normal running conditions to avoid failure
alignment of the gears and deflections of the shafts must be considered to prevent
their effect on the performance of the gears
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Design of Gears
Spur Gear Design
Spur Gear Tooth Force Analysis
W: Power Transmitted in kW
Mechanical Engineering Dept. CEME NUST
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stresses
Lewis considered
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd-Lewis Equation for Tooth Bending Stresscontd--
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd-Lewis Equation for Tooth Bending Stresscontd--
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd-Lewis Equation for Tooth Bending Stresscontd--
t and h are variables depending upon the size of tooth (i.e. Circular Pitch) and its profile
Let; t = x pc , and h = k pc ; where x and k are constants
Let
, another constant
WT= w bYm
(Y = y)
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd-Lewis Equation for Tooth Bending Stresscontd--
As
y is a function of Tooth Shape (but not size) and vary with the number of teeth in the gear
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd--
Lewis Equation for Tooth Bending Stresscontd-Spur Gear - graph for Modified Lewis Form Factor
WT= w bYm
w= WT/(bYm)
Since Y is in denominator, bending stresses w are higher for the 14 pressure angle
teeth, and for fewer number of teeth
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Design of Gears
Spur Gear Design
Spur Gear Tooth Stressescontd-Drawbacks of Lewis Equation
Tooth Load in practice is not static, It is dynamic and is influenced by pitch line velocity
whole load is carried by Single Tooth is not correct. Normally load is shared by teeth
since contact ratio is near to 1.5
Greatest force exerted at the tip of the tooth is not true as the load is shared by teeth. It
is exerted much below the tip when single pair contact occurs
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Design of Gears
Spur Gear Design
Permissible Working Stress for Gear Teeth in the Lewis Equation
permissible
Allowable Static Stress is the stress at the Elastic Limit of the material
To account for the Dynamic Effects which become more severe as the pitch
line velocity increases, the value of w is reduced
if a pair of gears failed at 500 lbf tangential load at zero velocity and at 250 lbf at
velocity V1, then a velocity factor, designated Cv, of 2 was specified for the gears at
velocity V1
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Design of Gears
Spur Gear Design
Permissible Working Stress for Gear Teeth in the Lewis Equationcontd--
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Design of Gears
Spur Gear Design
Dynamic Tooth Load
W D = WT + WI
increment load (WI) depends upon the pitch line velocity, the face width,
material of the gears, the accuracy of cut and the tangential load
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Design of Gears
Spur Gear Design
Dynamic Tooth Load
Maximum allowable tooth error in action (e) depends upon the pitch line
velocity (v) and the class of cut of the gears. Table 28.6 Book R.S. Khurmi
Static Tooth Load
Wear Tooth Load
Mechanical Engineering Dept. CEME NUST
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Design of Gears
Spur Gear Design
Design Procedure for Spur Gears
Step-1: designed tangential tooth load is obtained from the power transmitted and
the pitch line velocity by using the following relation:
m = Module in metres
T = Number of teeth
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Design of Gears
Spur Gear Design
Design Procedure for Spur Gearscontd--
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Design of Gears
Spur Gear Design
Design Procedure for Spur Gearscontd--
Lewis Equation is applied only to the weaker of the two wheels (i.e. pinion or gear)
When pinion and the gear are made of same material, then pinion is the weaker
When the pinion and the gear are made of different materials, then Lewis Equation is
used to that wheel for which (w y) or (o y) is less.
Face width (b) may be taken as 3pc to 4pc (or 9.5 m to 12.5 m) for cut teeth and 2pc to
3pc (or 6.5m to 9.5m) for cast teeth
Step-3: Calculate the dynamic load (WD) on the tooth by using Buckingham
Equation
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Design of Gears
Spur Gear Design
Example 7.2
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Design of Gears
Spur Gear Design
Example 7.3
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Design of Gears
Gear Trains
o
o
For Simple (Series) Train, numerical effects of all gears except the
first and last cancel out, i.e., Train Ratio is just the ratio of first gear
over the last
Intermediate gears are the Idlers, which changes only the sign of
the overall Train Ratio
NUST
Simplest form of gear train isMechanical
usuallyEngineering
limitedDept.
to aCEME
ratio
of about 10:1
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Design of Gears
Gear Trains
Compound Gear Trains
Gear Train in which at least one shaft carries more than one gear
o
o
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Subjective
Numerical Problems,
Ch: 1, 2, 4
20-30 Marks
Derivations,
Ch: 5
20-30 Marks
Short Questions
Ch: 6, 7
50 Marks
Formula sheet, standard tables etc. will be given within the Question Paper
Students are not allowed to bring any Formula Sheet/Table with them
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