MECH3030 Mechanisms of Machinery

Chap 6 Introduction to Gear Trains

Jaguar 3.8 Litre, 6 cylinder

Ref: Norton Chap 9
1
 Chapter 11: Introduction to Gear Trains

Spur gear: gear with radial teeth parallel to its axis

Rack and pinion: a mechanism in which a toothed wheel (pinion)

engages a notched bar (rack) to convert rotary motion into linear motion

Bevel Gear: Either of a pair of toothed wheels whose working surfaces are
inclined to nonparallel axes. Example: differential in automobile

Helical gear: a gear that has the teeth cut at an angle to the
center line of the gear. It can operate quieter than spur gear

Worm and gear : A coarse, spiral shaped gear cut on a shaft. It is used to
engage with and drive another gear or portion of a gear.

Herringbone Gears (double helical gears): two helical gears operating together
and so placed that the angle of the teeth form a "V" shape; cancel out end-thrust
forces
2
 Spur Gear
Axis of the gear

Spur gear: gear with radial teeth parallel to its axis

Backlash: the amount of "play" or clearance between two parts. For gears, it
refers to how much one gear can be moved back and forth without moving the
gear into which it is meshed
3
 Rack & Pinion, Bevel Gear ()

Pinion

Rack
Either of a pair of toothed
A mechanism in which a toothed wheel (pinion) wheels whose working surfaces
engages a notched bar (rack) to convert are inclined to nonparallel axes.
rotary motion into linear motion Example: differential in
-Allow bi-directional drive automobile
- rack-and-pinion steering in cars

Differential: a device that allows a difference in velocity (and displacement)

4 between two elements
 Helical Gears

Helical gear: a gear that has the teeth cut at an angle to the
center line of the gear. This kind of gear is useful because there is
no chance of intermittent tooth-to-tooth operation because there are
at least two teeth engaged at any time. It can operate quieter than
5
spur gear. Helical gears are either right- or left-handed.
 Worm Gear & Harmonic Gearing
Worm wheel
(worm gear)

Worm

A coarse, spiral shaped gear cut on a shaft. It is

used to engage with and drive another gear or Ultra low backlash gear technology
portion of a gear. As used in the steering gearbox,
with medium-high reduction ratios for
it often engages the cross shaft via a roller or by a
tapered pin.
accurate bi-directional repeatability,
high efficiency and power to weight.
Very high gear ratio is possible in small package
Good for motion control: robotics
6 Allow one directional drive: worm worm wheel
 Harmonic Gearing (Strain wave gear)

Wave Generator:
The wave generator is an oval-shaped cam. It is mounted onto the motor shaft
Flex Spline:
The flex spline is a thin, cup-shaped component made of elastic metal, with teeth
formed along the outer circumference of the cup's opening. The gear's output shaft is
attached to the bottom of the flex spline.
Circular Spline:
The circular spline is a rigid internal gear with teeth formed along its inner
circumference.
http://www.hds.co.jp/HDS_hp_english/english/products/index.html
http://www.harmonicdrive.net/reference/operatingprinciples/
7 http://www.youtube.com/watch?v=CSiHJPrycSA&feature=related
 Herringhbone Gear & Gear Train

Herringbone Gears (double helical gears): two

helical gears operating together and so placed
that the angle of the teeth form a "V" shape;
cancel out end-thrust forces. no thrust
bearing is needed
http://content.scvs.tpc.edu.tw/top1/chap10/htm/chap10-12.htm
8
 Differential Gear & Planetary Gear Train

http://www.youtube.com/watch?v=K4JhruinbWc
9
 Differential Operation

When turning a corner:

The wheels must travel at different speeds to prevent tire scrubbing

10
 Differential Operation
When turning a corner:
Differential pinion gears walk around slower side gear and cause
other side gear to turn faster
An equal percentage of speed is removed from one axle and given to
the other
The amount of torque applied to each wheel remains equal

11
 Limited-Slip Differentials

Provide more driving force to

the wheel with traction when
one wheel begins to slip
Still allow the wheels
to rotate at different
speeds when turning
a corner
Are sometimes
called Posi-Traction,
Traction-Lok,
and Posi-Units

12
 Limited-Slip Differential (LSD) - Torsen
Torsen differential
(torque sensing)
Designed by Vernon
Gleasman
GM
Audi
Lexus
Peugeot
Toyota
Volkswagen
13
 Limited-Slip Differential (LSD) - Torsen
When the torque bias ratio (TBR)
is less than than 3:1 one wheel
can receive up to 75% torque
The other will get 25%
When the TBR is GREATER
than 3:1 the worm wheels
tighten on the worm gear and
the slower side receives torque
from the faster side

14
 Tochigi Fuji Sangyuo ()
GKN Driveline: Limited-Slip Differential (LSD)

Torque Management Device (TMD)

- Active TMD
Electronic Torque Manager (ETM)
Electro-magnetic Control Device
Electronic Torque Vectoring
- Passive TMD
Visco Lok LSD, Viscous Coupling, Super LSD,
Helical LSD, Multi-plate LSD

15
 Four-Wheel Drive (4WD)

16
 4WD Purpose
Provide additional traction for off-road or poor
traction conditions
May provide a low range for increased torque
Some units may have provisions for PTO (Power
Take-Off)

17
 4WD VS. AWD
4WD
Generally is part-time
Generally provides a low range
AWD
Generally is full-time
Generally does not provide a low range
Generally contains a front to rear differential

http://www.youtube.com/watch?v=vuUaqFnsb2M

18
 Components
Two drive axle assemblies
Front axle must be able to steer as well as drive
Gear ratios must match (front to rear)
Front drive axles have traditionally been solid (non-
independent)
Independent front suspension is becoming much more
popular
Some AWD vehicles are built off of a FWD platform

19
 Components
Transfer Case
An auxiliary transmission designed to split power between the
front and rear drive axles
Lock out hubs used to disengage the front wheels from
the drive axle
Increases highway fuel economy and reduces wear
May be automatic or manual
Automatic hubs react to input torque when transfer case is shifted into
4WD
May not unlock after shifting out of 4WD until vehicle is backed up (30-50ft)

20
 Components

21
 AM Generals Humvee, Hummer ()

1979: Armys High Mobility Multipurpose Wheeled Vehicle (HMMWV)

US$1.2billion for 55k Humvees, US$1.6billion for 70k Humvees
22
 AM Generals Hummer (), Civilian

23
 2011 Jeep Grand Cherokee - Drive Train

Quadra-Trac I
A light-weight single-speed case that automatically delivers full-time four-wheel drive.
Quadra-Trac II
Two-speed transfer case, with multiple sensors to detect tire slip, can direct up to 100 percent of available
torque to the axle with the most traction.
Quadra-Drive II
The industry leader in tractive capability, Quadra Drive II with Electronic Limited-slip Differential (ELSD) has a
4WD Low range mode that multiplies torque 2.72 times and locks clutch packs in the center differential for
24 performance in the most extreme conditions.
 Kinematics of Gears

v A v O v A / O 0 1 r A / O
1k r1i 1r1 j

v A v P v A / P 0 2 rA / P
2k (r2i) 2 r2 j

2 r1
1r1 2 r2 or
1 r2
Fundamental law of gearing:
Angular vel. Ratio = constant throughout the mesh torque ratio
25
 How can the radii r1 and r2 be related to the number of
teeth on each gear?

Assume that the gears must have the same circular pitch

n1 = teeth on gear 1
n2 = teeth on gear 2

Pitch: the distance between a point on one gear tooth and the same
point on the next gear tooth

26
 Simple gear set

O/P
I/P

Here, gears 3 & 4 are rigidly connected, as are gears 5 & 6

3 n2 5 n4 7 n6

2 4 n5
n3 n 6 7

Clearly 4 = 3 and 6 = 5
7 3 5 7 n 2 n 4 n6

2 2 4 6 n3 n5 n7
27 The sign is necessary to take into account the change in direction of rotation.
 Reverted gear train

1 2

Used in automotive transmission: Compare:

- compact, save space

Revert = go back to a previous state

28
 Internal gear

3 r2 n2

2 r3 n3

The + sign is used here to take into

account the direction of rotation.

29
 Example: Find the speed reductions possible for the
transmission 4 = Gear number 22 = Gear teeth number

the power is transmitted

through gears 0456
1012.

If gear 34 slides to the left (disengaging 4 from 5) and gear 12 to the left
(engaging 1 and 9), then power is transmitted through 01961012

30
 Example: Find the speed reductions possible for the
transmission
gear 12 gear 34
If gear 34 slides to the left
(disengaging 4 from 5) and
gear 12 to the left (engaging
1 and 9), then power is
transmitted through 0196
1012

Note: There are 8 possible speed

reductions.
31
 Example: Find the gear reductions in the automotive transmission

Low gear: gear 3 meshes with

gear 6, power flows 1463.
Second gear: gear 2 meshes
with gear 5, power flows 14
52.
High gear: gear 2 is shifted so
that the clutch teeth on the
end of gear 2 mesh with the
clutch teeth of gear 1.
(Direct drive results.)
Reverse gear: gear 3 is shifted
to mesh with gear 8, power
flows 14783.
http://auto.howstuffworks.com/transmission3.htm

http://www.mattsauto.com/trans.html
http://www.youtube.com/watch?v=o-3SqMsgVdI
How Manual Transmission Works
32
 Example: Find the gear reductions in the automotive transmission
power flows 1463

out
3
in low 1
4 6 3

1 4 6
n n
1 (1) 6
n4 n3
14 18
power flows 1452. 0.301
31 27
out
2
in 2nd 1
4 5 2

1 4 5 out
1.000
n n
1 (1) 5 in Hi
n4 n2
14 25
0.564
33 31 20
 Example: Find the gear reductions in the automotive transmission

power flows 14783.

out
3
in rev 1
4 7 8 3

1 4 7 8
n1 n7 n8
(1)
n4 n8 n3
14 14
0.234
31 27

34
 Planetary gear train
Example: Find the output angular velocity 2 for the planetary gear train shown
when the input angular velocity is 4 = 50 rad/sec counterclockwise.

annulus
Note that gear 2 and
arm 4 are not joined.
Sun (O/P) planet v A v C 3 rA/C
4
4 k (r2 r3 )i 3k (r3i )
2 [(r2 r3 ) 4 r3 3 ]j
arm

v A 2 rA/O
1 annulus (80) (internal gear) 2 k r2 i
2 sun gear (40) r2 2 j
3 planet gear (20) (1)
4 arm
Program: 9-33.wm2d
r22 (r2 r3 )4 r33
35
 (2) v B v C v B/C n2 = 40
n3 = 20
0 4 k rC / O 3k rB / C
4 k (r2 r3 )i 3k r3i
(r2 r3 ) 4 j r3 3 j
using the tooth relationship to replace the radii,

Substituting back into the other equation gives

36
 Example: Find the gear ratios for the model T Ford gearbox
P1 2: On
P2 http://auto.howstuffworks.com/clutch.htm

I/P
O/P
Gearbox : Integral with the engine. Foot
operated 2 speed and reverse epicyclic
transmission foot-brake, 1908 for 19 yrs

S1 9 million were made!

S2
http://www.t-ford.co.uk/car.htm

Textbook p.507
37
 Low gear for the model T Ford

Point B

in

Point C
in
out

Replacing the radii by the number of teeth

on the appropriate gears

http://auto.howstuffworks.com/transmission.htm
38
 Example: Reversed Gear case
P1 1:On
P2

I/P
O/P

S2 S1

Textbook p.507
39
 Reverse gear for the model T Ford

in

out

Note the negative sign indicating a change in direction

40
 Reverse on a Car

http://www.innerauto.com/Automotive_Animations
41
 Model T Ford, 1912 Landaulette

42
 Towards the Involute Profile

A belt connecting the two cylinders

The involute is a curve traced by a point on a taut, inextensible

string as it unwinds from a circle.

http://www.ies.co.jp/math/java/calc/en-circum/en-circum.html

43
 The Involute Profile

-The string is always tangent to the cylinder

-The center of curvature of the involute is always at the point of
tangency of the string with the cylinder
-A tangent to Involute is then always normal to String, the length
of which is the instantaneous radius of curvature of Involute curve

Involute curve: created by tying a pencil to the end of a string and wrapping the string
around a cylinder. Hold tension in the string as you unwind it from the cylinder. The
curve drawn by the pencil as it moves out from the cylinder is an involute curve.
44
 Profile of the Involute Profile
Pressure angle = the angle between Line of Action (common normal) and the
direction of velocity at the pitch point (has been standardized: 14.5
, 20
, 25
)
Common
tangent

Line of action (common
normal)

Line of action (common normal): A line normal to a pair of mating tooth profiles at their point of contact
45
 Involute in Action

Pitch circle=rolling cylinder circle

Addendum: the amount of tooth that sticks out above the pitch circle

video from http://www.howstuffworks.com http://en.wikipedia.org/wiki/Involute_gear

Fundamental law of gearing: the common normal of the tooth profiles, at all contact
points within the mesh, must always pass through a fixed point on the line of centers,
called the pitch point
46
 Nomenclature pc
d
N

Figure 11-8
47
 Pitches, Etc.

circular pitch (mm, in.) d

pc
N
base pitch (mm, in.) pb pc cos
N
diametral pitch (teeth/in.): US pd
d
module (mm/teeth): SI d
m
N

48
 Minimum # of Teeth
minimum # of teeth to avoid undercutting with gear and rack

2
N min 2
sin = pressure angle

49
 Involute curve for involute gear

x a(cos sin )
y a(sin cos )
a = diameter of base circle

Commonly used in all kinds of power

transmission systems:

The center-to-ceter distance between two involute gears (common error in

manufacturing process) will not affect the velocity ratio!

http://mathworld.wolfram.com/CircleInvolute.html Antons Calculus (7th): p.782

50
 Origin of involute curve
T
t = angle
r

-sT
r

ri

x a(cos sin )
y a(sin cos )
51
 Involute curve for tooth profile

52
 Involute curve for tooth profile

arc DG BG
DOG
OG OG
BG
tan B
OG
DOG tan B
DOB DOG B tan B B
DOA tan A A
0.5t B t
DOE DOB (tan B B ) B
RB 2 RB
0.5t A t
DOE DOA (tan A A ) A
RA 2RA

tA
t B 2 RB (tan A A ) (tan B B )
tA & tB = the tooth thickness at R = RA, A
2 R
RB respectively
53
 Involute curve for tooth profile

54
55
 Cycloid curve for cycloidal gear

Commonly used in watches and clocks

P(x,y)
x a a sin
y a a cos
http://mathworld.wolfram.com/Cycloid.html
The cycloid is the locus of a point on the rim of a
circle of radius rolling along a straight line Antons Calculus (7th): p.93
56
 Rack & Pinion

57
 Bevel Gear

58
 Worm Gear

59
 Gear Train

60
 Automotive Differential Gear

61
 Manual Transmission
Low gear Second gear

62
 Gear Types Grouped According to Shaft Arrangement

Straight bevel: These are like spur gears, the teeth have no helix angle
Spiral bevel gears: Teeth have a spiral angle which gives performance improvements much
like helical gears
Zerol bevel gears: Teeth are crowned, so that tooth contact takes place first at the tooth
center. (Zerol Bevel Gears are Spiral Bevel Gears with a spiral angle of zero)
Hypoid gears: Similar to spiral bevel gears, but connect non-parallel shafts. The pitch
surface of this gear is a hyperboloid of revolution (rather than a cone, the pitch surface in
bevel gears). It is stronger, operate quietly, used for higher reduction ratios. Hypoid gears
are found in auto differentials.
63
 Herringbone gears examples

from D.O. James Gear Manufacturing Co.

http://www.linngear.com/products/highlights/infosheets/g-3.html
64
 Comparision between Helical Gear and Herringbone Gear

65
 Bevel Gear: based on rolling cones

Apices must be
conincident

Incorrect arrangement Correct arrangements

66
 Spiral bevel Gear & Hypoid Gear

Spiral bevel Gears Hypoid Gears are similar in their general

form to bevel gears. However, Hypoid
Gears operate on non-intersecting axes.
(Hypoid = a contradiction of hyperboloid)

67
 Hypoid Gear: based on hyperboloids of revolution

Rolling hyperboloids of Automotive hypoid final drive gears

revolution (General Motors, Detroit, MI)
Hyperboloids: quadric surface generated by rotating a hyperbola around its
68 main axis (http://mathworld.wolfram.com/Hyperboloid.html)
 Hypoid Gears
The centerline of the drive pinion gear intersects
the ring gear at a point lower than the centerline
They are commonly used in cars and light-duty
trucks
Their design allows for a lower vehicle height and
more passenger room inside the vehicle

69
 Spiral Bevel Gears
The centerline of the drive pinion intersects
the centerline of the ring gear
They are usually used in heavy-duty truck applications
They are usually noisier than hypoid gears

70
 Example: Automotive steering

71
 Mechanism in Cars

72
 Automatic Transmission in Cars (animation)

http://auto.howstuffworks.com/automatic-transmission6.htm

73
 How Automatic Transmissions Work
http://auto.howstuffworks.com/automatic-transmission.htm
http://auto.howstuffworks.com/automatic-transmission18.htm

74
 How Automatic Transmissions Work

75
 How Automatic Transmissions Work

Planetary Gear Sets

Hydraulic System: transmission fluid via Oil Pump through the Valve
Body to control the Clutches and the Bands in order to control the planetary
gear sets.

Seals and Gaskets are used to keep the oil where it is supposed to be
and prevent it from leaking out.

The Torque Converter which acts like a clutch to allow the vehicle to
come to a stop in gear while the engine is still running.

The Governor and the Modulator or Throttle Cable that monitor

speed and throttle position in order to determine when to shift.

76
 How Automatic Transmissions Work

1. Provides automated control of vehicle launch

(starting the vehicle from a stop)
2. Selects the desired gear ratio
3. Shifts to the desired gear ratio
4. Modifies the engine's speed/torque
5. Transmits power efficiently (helps provide good fuel
economy)

77
 Helical Gears

78
 Spur Gears with Full Depth 14 and Stub 20

79
 How to make a gear: gear hobbing or CNC machining

Gear hobbing =
a multipoint machining process
gear teeth are progressively generated by a series of
cuts with a helical cutting tool (hob)
Both Hob & Workpiece revolve constantly as Hob is
fed across the face width of the gear blank

Gear generating process uses a helical hob cutter

Cutters and blanks rotate in a timed relationship
Maintains a proportional feed rate between the gear blank
and the hob
Cuts several teeth on a progressive basis
used for high production runs

Hob = a hard steel edge tool to cut gears

80
 Length of Action Z for Gear (rg) and Pinion (rp)

Fig 9-6

Z (rp a p ) 2 (rp cos ) 2 (rg ag ) 2 (rg cos ) 2 C sin

81
 Length of Action Z for Gear (rg) and Pinion (rp)

Fig 9-7 Z (rp a p ) 2 (rp cos ) 2 (rg ag ) 2 (rg cos ) 2 C sin

C = center distance, Contact ratio mp = avg number of teeth in contact at any one time
= Z / pb
pb = base pitch = pc cos mp, min=1.2 m p, spur = (1.4, 2)
82
 Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 19, Ngear = 37

Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
Gear ratio: mG = Ngear / Npinion = 37/19 = 1.947

Circular pitch pc = /pd = /6 = 0.524 in

Base ptich pb = pc cos = 0.524 cos(20)=0.492 in

83
 Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37

Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
Pinions pitch diameter dp = Np /pd = 19/6 = 3.167 in, rp = dp /2 = 1.583 in

Gears pitch diamter dg =Ng /pd = 37/6 = 6.167 in, rg = dg / 2 = 3.083 in

Nominal center distance C = sum of pitch radii

C = rp + rg = 4.667 in

84
 Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37

Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearance, Ro, contact ratio of gearset with given parameters

Sol:
From Tabel 9-1 (p. 471):

Addendum a = 1.0/pd = 0.167 in Dedendum b = 1.25/pd = 0.208 in

Whole depth ht = sum of a & b = 0.167 + 0.208 = 0.375 in

Clearance = difference between dedendum and addendum

c = b-a = 0.208 0.167 = 0.042 in

85
 Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37

Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
From Tabel 9-1 (p. 471):

Outside diameter of each gear = pitch diameter plus 2 addenda

Dop= dp + 2a = 3.500 in Dog= dg + 2a = 6.500 in

86
 Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37

Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Z (rp a p ) 2 (rp cos ) 2 (rg a g ) 2 (rg cos ) 2 C sin

(1.583 0.167) 2 (1.583 cos 20) 2 (3.083 0.167) 2 (3.083 cos 20) 2 4.667 sin 20
0.798 in

Contact ratio mp = Z/pb = 0.798/0.492 = 1.62

87
88