Gears

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 Gears
Parallel&Gearing

Right&Angle&Gearing
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 Types of Gears

Spur%Gear:% Helical%Gear:% Worm%and%

Transmits&mo3on& Transmits&mo3on& Worm%Gear:%
Bevel%Gear:% Used&for&large&
between&parallel& between&parallel& Transmits&mo3on& speed&ra3o&
and&non:parallel& between&
sha7s.&Less&noisy& intersec3ng&
sha7s&
Nomenclature – Spur Gears
 Important Quantities
Pitch Circle: Theoretical Circle.
Pitch circles of a pair of mating gears are parallel to each other
Smaller Mating Gear: Pinion
Larger Mating Gear: Gear
Circular Pitch (p): Distance between a point on one tooth to the corresponding
point on an adjacent tooth.
p = (tooth thickness + width of space)
pitch circle dia d πd
Module: m= = ⇒ p= = πm
no. of teeth N N
N 1
Diametral Pitch: P= =
d m
Addendum: a = radial distance between top land and pitch circle
Dedendum: b = radial distance between bottom land and pitch circle
Clearance Circle: circle tangent to the addeddum circle of mating gear
Clearance: c=b−a
Back lash: difference between width of tooth space and thickness of
the engaging tooth on mating gear on pitch circle
 Gears – Angular Velocity Ratio

From the velocities of point A (on bodies 1 and 2)

vA1 cos φ = vA2 cosψ Source:&Kinema'c)analysis)and)synthesis)of)
ω 1 .O1 A1 cos φ = ω 2 .O2 A2 cosψ mechanisms)by&Mallik,&Ghosh&and&DiGrich&

ω 1 O2T O2 P
= =
ω 2 O1S O1P
(From the similarity of triangles ΔO1SP and ΔO2TP)
Constant Angular Velocity Ratio
Can&be&achieved&using&a&belt&pulley&system:&
Angular&velocity&ra3o&is&same&as&the&inverse&ra3o&of&the&diameters

Source:&Kinema'c)analysis)and)synthesis)of)
mechanisms)by&Mallik,&Ghosh&and&DiGrich&
Involute Profile
The curves on the shaded
area are the involute
profiles.

Obtained by tracing the

point Q on the shaded
flanges attached to pulleys
1 and 2.

Source:&Kinema'c)analysis)and)synthesis)of)
mechanisms)by&Mallik,&Ghosh&and&DiGrich&
Involute Profile
Path of contact is always the
line AB.

Thus the situation is same as the

crossed belt and pulley system

Constant angular velocity ratio

is maintained.

Source:&Kinema'c)analysis)and)synthesis)of)
mechanisms)by&Mallik,&Ghosh&and&DiGrich&
CONJUGATE ACTION
 Conjugate Action – Law of Gearing

Conjugate&Ac3on Conjugate&Ac3on&in&Gears Involute&Profile

Conjugate*Ac-on:*%&Maintains&constant&speed&ra3o&during&mo3on&transfer&
& & & & &&&&Provides&jerk:free&&and&smooth&mo3on&transmission&

Involute*Profile:*%&&&&&One&way&to&get&conjugate&ac3on&
& & & & &&&&Predominantly&used&for&gear&tooth&profile&
 Pressure Angle
Contact/Pressure&line:

Involute&Profile
ab:%%% % Contact%Line%or%Pressure%Line%(locus&of&contact&point&between&ma3ng&teeth)&
& & & Conact%line%always&normal&to&tooth&profile.&Contact&force&acts&along&this&line&
φ :% % % Pressure&Angle&
Gear 2: r = O2 P = pitch circle radius; rb = O2 b = base circle radius
rb = r cos φ; base pitch pb = p cos φ
 Arc of action and Contact Ratio

• Arc of action:
qt = qa + qr

• First contact: a

• Final contact: b
q t = p (circular pitch) ⇒ At any instant one one pair of teeth in action
qt > p ⇒ A new pair gets into contact before already
engaged pair reaches final contact
qt Lab Lab
Contact Ratio: mc = = =
p p cos φ pb
Recommended: mc ≥ 1.2 (to avoid mounting inaccuracies)
Interference:
Interference
- Happens due to contact between non-conjugate portion of teeth
- Example: contact occurring in the clearance region
- Causes removal of flank
To avoid interference: undercutting (involute profile below base circle) is done
undercutting makes tooth weaker

To avoid interference without under cutting:

NP ≥
2k
(1 + 2mG )sin φ
2 (
m G + m 2
G + (1 + 2mG )sin 2
φ )
N P := number of teeth on pinion
N G := number of teeth on gear
NG
mG = := gear ratio
NP
⎧
⎪ 1 for full depth teeth
k=⎨
⎪ 0.8 for stub teeth (shorter hight)
⎩

See&Table&13:1&to&13:4&for&tooth&systems,&values&of&pressure&angle,&addendum&etc.&
INTERFERENCE
 Gear Mesh Design – Spur and Helical
Useful quantities:
Diameters (pinion and dear): dP and dG ;

Number of teeth (pinion and gear): N P and N G

pitch circle diameter dP dG

Module: m = = = ;
Number of teeth N P NG
π d P π dG
Circular pitch: p = = =πm
Np NG
N P NG 1
Diametral pitch: P = = =
dp dG m
Addendum: a;
Deddendum: d
 Gear Force Analysis
60000H π dn
Transmitted Load: Wt = (in kN); Pitch line velocity: V = (in m/sec)
π dn 60000
H := Transmitted power in kW
d := gear/pinion diameter in mm
n := speed in rpm

Helical gear:
Wt
Normal tooth force : W = ;
cos φt cosψ
Radial tooth force : Wr = Wt tan φ;
Axial tooth force : Wa = Wt tan ψ

Spur gear (set helix angle ψ = 0):

Wt
Normal tooth force : W = ;
cos φ
Radial tooth force : Wr = Wt tan φ
AGMA Equations for Bending (SI Units)
AGMA Stress Equation for Bending:
Wt K H K B
σ = KoKvKs
bmt YJ
Wt := Transimtted load (tangential) in N; b := face width in mm;
mt := Transverse metric module in mm (for spur gear mt = m)
K o := Overload factor (Figure 14-17 or 14-18)
K v := Dynamic factor (Figure 14-9 or Eq. 14-27 and 14-28)
K s := Size factor ( =1 )
K B := Rim thickness factor (Eq. 14-40 or Figure 14-16)
YJ := Geometry factor for bending resistance (For spur gear Figure 14-6)
(For helical gear Figures 14-7 and 14-8)
K H := Load distribution factor (See table below)
Condition of support Face width
Up to 50 mm Up to 150 mm Up to 225 mm Up to 400 mm

Accurate mounting, low bearing clearances, 1.3 1.4 1.5 1.8

minimum elastic deflection, precision gears
Less rigid mounting, less accurate gears, contact 1.6 1.7 1.8 2.0
across full face
Accuracy and mounting such that less than full-face Over 2.0
contact exists
AGMA Equations for Bending (SI Units)
AGMA Strength Equation for Bending:
St YN
σ all =
SF YθYZ

St := Allowable bending stress (in N/mm 2 ) for 0.99 reliability and 10 7 cycles
(Tables 14-3, 14-4; Figures 14-2, 14-3, 14-4)
YN := Stress-cycle factor for bending stress (Figure 14-14)
Yθ := Temperature factor (=1 for less than 100°C)
YZ := Reliability factor (Table 14-10)

σ all
SF := AGMA factor of safety (calculate in the end as SF = );
σ
 AGMA Equations for Pitting (SI Units)
AGMA Stress Equation for Contact (pitting):
Wt K H Z R
σ c = ZE KoKvKs
bd p Z I
Wt := Transimtted load (tangential) in N;
d p = mN P (Pinion diameter in mm)
Z E := Elactic coefficient in N/mm 2 ; (Table 14-8 or Eq. 14-13)
Z R := Surface condition factor ( Take equal to unity)
Z I := Geometry factor for pitting resistance (Eq. 14-23 along with 14-12, 14-24, 14-25)
AGMA Equations for Pitting (SI Units)
AGMA Strength Equation for Pitting:
SC Z N ZW
σ c,all =
SH YθYZ
Sc := Allowable contact stress (in N/mm 2 ) for 0.99 reliability and 10 7 cycles
(Tables 14-6, 14-7; Figure 14-5)
Z N := Stress-cycle factor for contact stress (Figure 14-15)
ZW := Hardness ratio factor for pitting resistance
(For pinion Z w = 1; For gear - Figures 14-12, 14-13)
σ c,all
SH := AGMA factor of safety for pitting (calculate in the end as SH = )
σc

Note: Compare (SF ) and (S H )2 to decide whether bending or wear is the threat to gear function
 Gear Mesh Design – Spur and Helical
Criteria:
Load, speed, reliability, life (N), overload (Ko),
design factor (nd)
Apriori Decisions:
Pressure angle (φ), Helix angle (ψ)
Addendum (a), Deddendum (d), root fillet radius (rF)
Gear Ratio (mG), Number of teeth (Np, NG)
Quality Number (Qv)

Design Decisions:
Module (m), Face width (b)
Pinion Material, core hardness, case hardness
Gear Material core hardness, case hardness
 Design Steps
1. Choose a module:

2. Check for Pinion bending and wear (pitting)

i. Choose material and a core hardness
ii. Calculate face width to satisfy safety factor and standardize
(ensure 3π m ≤ b ≤ 5π m)
iii. Compute AGMA factors of safety SF and SH
iv. If not satisfactory modify module and repeat until the design is
satisfactory

3. Check for Gear bending and wear (pitting)

i. Choose material and a core hardness
ii. Compute AGMA factors of safety SF and SH
iii. If not satisfactory modify module and repeat until the design is
satisfactory