Law of toothed gearing – Involutes and cycloidal tooth profiles –Spur Gear

terminology and definitions –Gear tooth action – contact ratio – Interference and
undercutting. Helical, Bevel, Worm, Rack and Pinion gears [Basics only]. Gear
trains – Speed ratio, train value – Parallel axis gear trains – Epicyclic Gear Trains

2 MARKS: Q & A

SPUR GEAR TERMINOLOGY AND DEFINITIONS

1. State law of Gearing. [Nov/Dec-07, May/June-14,17]
 The law of gearing states that for obtaining a constant velocity ratio, at any instant of teeth the
common normal at each point of contact should always pass through a pitch point, situated on the
line joining the centre of rotation of the pair of mating gears.

2. Define normal and axial pitch in helical gears. [May/June-2016]

 Normal pitch is the distance between similar face of adjacent teeth, along a helix on the pitch
cylinder normal to the teeth.
Axial pitch is the distance measured parallel to the axis between similar faces of a adjacent teeth.

3. What is the maximum efficiency in worm and worm gear?

 max = 1-sinφ/1+sinφ

4. What are the advantages and limitations of gear drive? Write any two.
Advantages:
1. Since there is no slip, so exact velocity ratio is obtained.
2. It is more efficient and effective means of power transmission.
Limitations:
1. Manufacture of gear is complicated.
2. The error in cutting teeth may cause vibration and noise during operation.
5. Define cycloidal tooth profile and involute tooth profile. [Nov/Dec-14 ]
 A cycloid is the curve traced by a point on the circumference of a circle which rolls without slipping
on a fixed straight line.
 Involute profile is defined as the locus of a point on a straight line which rolls without slipping on
the circumference of a circle.

6. Define circular pitch and diametral pitch in spur gears. [May/June-06][Nov 16]
Circular pitch (pc): It is the distance measured along the circumference of the pitch circle from a
point on one teeth to the corresponding point on the adjacent tooth.
pc=πD/T
Diametral pitch (PD): It is the ratio of number of teeth to the pitch circle diameter. PD=T/D=π/pc
7. Define Backslash.
 It is the difference between the tooth space and the tooth thickness along the pitch circle.
Backslash = Tooth space – Tooth thickness

8. Define the following terms used in gear (a) pressure angle(b) module[May/June12]
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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. It is usually denoted by φ. The standard pressure angles are
12 14 ° and 20°.
Module: [Nov 16]
 It is the ratio of the pitch circle diameter in millimeters to the number of teeth.
 It is usually denoted by m. Mathematically, Module, m = D /T

9. Define gear ratio. [Nov/Dec-13]

 It is the ratio of number of teeth on wheel to the number of teeth on pinion.
G = Gear ratio = T / t Where, t = Number of teeth on the pinion, T = Number of
teeth on the wheel,

10. Define the term arc of contact in gears. [Nov/Dec-12]

Arc of contact: It is the path traced by a point on the pitch circle from the beginning to the end
of engagement of a given pair of teeth. The arc of contact consists of two parts, i.e.
(a) Arc of approach: It is the portion of the path of contact from the beginning of the
engagement to the pitch point.
(b) Arc of recess: It is the portion of the path of contact from the pitch point to the end of the
engagement of a pair of teeth.

11. What is the condition stated by the law of gearing? [May/June-13]

 The common normal at the point of contact between a pair of teeth must always pass through the
pitch point. This is the fundamental condition which must be satisfied while designing the profiles
for the teeth of gear wheels. It is also known as law of gearing.

12. List down the common forms of teeth. [May/June-13]

 1. Cycloidal teeth; and 2. Involute teeth

13. What do you know about tumbler gear?

 Tumbler gears are those which are used in lathes for reversing the direction of rotation of driven
gears.

14. What you meant by non-standard gear teeth? [May/June-07]

 The gear tooth obtained by modifying the standard proportions of gear teeth parameters is known
as non- standard gear teeth.

15. What is bevel gearing? Mention its types.

 When the non-parallel (or) intersecting but coplanar shafts connected by gears, they are called
bevel gears and the arrangement is bevel gearing. It is of two types namely skew bevel gearing
and spiral gearing.

16. What is an angle of obliquity in gears?

 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. It is called as pressure angle.

17. Define Contact Ratio. [Nov/Dec-06]

 It is the ratio of the length of arc contact to the circular pitch is known as contact ratio. The value
gives the number of pairs of teeth in contact.
18. Write down the difference between involute and cycloidal tooth profile.
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 S.N Involute Tooth Profile Cycloidal Tooth Profile
o
1. Variation in centre distance does not affect the The centre distance should not vary.
velocity ratio.
2. Pressure angle remains constant throughout the Pressure angle varies. It is zero at the pitch
teeth. point and maximum at the start and end of
engagement.
3. Interference occurs. No interference occurs.
4. Weaker teeth. Stronger teeth.

INTERFERENCE AND UNDERCUTTING

19. Define interference and under cutting of gears. [Nov/Dec-14 & 16]
 The phenomenon when the tip of tooth undercuts the roots on its mating gear is known as
interference.
 The profile of tooth inside the base circle is radial. If the addendum of mating gear is more than
the limiting value, it interferes with the dedendum of pinion and therefore two gears get locked.
However, if a cutting rack having similar teeth is used to cut the teeth in the pinion, it will
remove that portion of the pinion tooth which would have interfered with gear. A gear having
its material removed in this manner is said to undercut and the process, undercutting of gears.

20. What are the methods to avoid interference? [May/June-2014] [Nov/Dec-14]

1. The height of the teeth may be reduced.
2. The pressure angle may be increased.
3. The radial flank of the pinion may be cut back (undercutting).

21. What is the advantage when arc of recess is equal to arc of approach in meshing gears?
[May/June-2016]
 When arc of recess equal to arc of approach, the work wasted by friction is minimum and efficiency
of drive is maximum.

GEAR TRAINS

22. What is gear train of train of wheels?

 Two or more gears re made to mesh with each other to transmit power from one shaft to another.
Such a combination is called a gear train or train of wheels.

23. Write velocity ratio in compound train of wheels? [May/June-06]

 Speed of last follower - Product of teeth on drivers
 Speed of first driver – Product of teeth on followers.

24. Give the classification of gears based on position of teeth on the wheel. (Nov/Dec-17)
 Straight
 Inclined
 Curved

25. What is reverted gear train? [Nov/Dec-06]

 When the axes of the first and last wheels are co-axial, the train is known as reverted gear train.

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26. Where the epicyclic gear trains are used? [April /May-10]
 The epicyclic gear trains are used in the back gear of lathe, differential gears of the automobiles,
pulley blocks, wrist watches, etc.

27. What is meant by compound gear train (or) Draw the compound gear train and write its
speed ratio. ( N/D-17)
 When there is more than one gear on shaft, it is called a compound gear train.

28. What is the advantage of a compound gear train over a simple gear train? [April/May-05]
 The advantage of a compound gear 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.

29. State the methods to find the velocity ratio of epicyclic gear train. [Nov/Dec-09]
Two methods are:
1) Tabulation method.
2) Algebraic method.

30. What is the externally applied torques used to keep the gear train in equilibrium?
1) Impart torque on the driving member.
2) Resisting or holding torque on the driven member.
3) Holding or braking torque on the fixed member.
31. What are the roles of idlers in gear trains? [May/June12]
1. To connect gears where a large centre distance is required, and
2. To obtain the desired direction of motion of the driven gear (i.e. clockwise or anticlockwise)
32. Name two application of reverted gear train. [Nov/Dec-12]
 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).

33. What is epicylic gear train? Give a practical example.[Nov/Dec-11]

 In an epicyclic gear train, the axes of the shafts, over which the gears are mounted, may move
relative to a fixed axis.
 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, wrist watches etc.
34. What is the use of differential in automobile? [Nov/Dec-11,13]
(a) To transmit motion from the engine shaft to the rear driving wheels, and
(b) To rotate the rear wheels at different speeds while the automobile is taking a turn.
35. What type of gear arrangement is used to traverse the carriage in lathe machine.(M/J-17)
 Tumbler gear

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 16 MARKS: Q & A
PROBLEMS BASED ON INVOLUTE GEARS – R.S KHURMI
1. The number of teeth on each of the two equal spur gears in mesh are 40. The teeth have 20°
in volute profile and the module is 6 mm. If the arc of contact is 1.75 times the circular pitch,
find the addendum. [Nov/Dec-06]

Solution.

Given : T = t = 40 ; φ = 20° ; m = 6 mm

2. A pinion having 30 teeth drives a gear having 80 teeth. The profile of the gears is in volute
with 20° pressure angle, 12 mm module and 10 mm addendum. Find the length of path of
contact, arc of contact and the contact ratio. (N/D-17)

Solution. Given : t = 30 ; T = 80 ; φ = 20° ; m = 12 mm ; Addendum = 10 mm

5
3. Two in volute gears of 20° pressure angle are in mesh. The number of teeth on pinion is 20
and the gear ratio is 2. If the pitch expressed in module is 5 mm and the pitch line speed is 1.2
m/s, assuming addendum as standard and equal to one module, find :
1. The angle turned through by pinion when one pair of teeth is in mesh ; and
2. The maximum velocity of sliding. [Nov/Dec-11]
Solution.
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Given : φ = 20° ; t = 20; G = T/t = 2; m = 5 mm ; v = 1.2 m/s ; addendum = 1 module = 5 mm

7
4. A pair of gears, having 40 and 20 teeth respectively, are rotating in mesh, the speed of the
smaller being 2000 r.p.m. Determine the velocity of sliding between the gear teeth faces at the
point of engagement, at the pitch point, and at the point of disengagement if the smaller gear
is the driver. Assume that the gear teeth are 20° involute form, addendum length is 5 mm and
the module is 5 mm. Also find the angle through which the pinion turns while any pairs of teeth
are in contact.

Solution.
Given : T = 40 ; t = 20 ; N1 = 2000 r.p.m. ; φ = 20° ; addendum = 5 mm ; m=5mm

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5. The following data relate to a pair of 20° in volute gears in mesh: Module = 6 mm, Number of
teeth on pinion = 17, Number of teeth on gear = 49 ; Addenda on pinion and gear wheel = 1
module. Find: 1. The number of pairs of teeth in contact; 2. The angle turned through by the
pinion and the gear wheel when one pair of teeth is in contact, and 3. The ratio of sliding to
rolling motion when the tip of a tooth on the larger wheel (i) is just making contact, (ii) is just
leaving contact with its mating tooth, and (iii) is at the pitch point.(M/J-17)

Solution. Given : φ = 20° ; m = 6 mm ; t = 17 ; T = 49 ; Addenda on pinion and gear wheel = 1 module = 6 mm

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10
6. A pinion having 18 teeth engages with an internal gear having 72 teeth. If the gears have in
volute profiled teeth with 20° pressure angle, module of 4 mm and the addenda on pinion and
gear are 8.5 mm and 3.5 mm respectively, find the length of path of contact.

Solution. Given : t = 18 ; T = 72 ; φ = 20° ; m = 4 mm ; Addendum on pinion = 8.5 mm ; Addendum on gear =

3.5 mm

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12
INTERFERENCE IN INVOLUTE GEARS

7. Two mating gears have 20 and 40 in volute teeth of module 10 mm and 20° pressure angle.
The addendum on each wheel is to be made of such a length that the line of contact on each
side of the pitch point has half the maximum possible length. Determine the addendum height
for each gear wheel, length of the path of contact, arc of contact and contact ratio. [Nov 16]

Solution. Given : t = 20 ; T = 40 ; m = 10 mm ; φ = 20°

Addendum height for each gear wheel

We know that the pitch circle radius of the smaller gear wheel,

r = m.t / 2 = 10 × 20 / 2 = 100 mm

and pitch circle radius of the larger gear wheel,

R = m.T / 2 = 10 × 40 / 2 = 200 mm

Let RA = Radius of addendum circle for the larger gear wheel, and

rA = Radius of addendum circle for the smaller gear wheel.

Since the addendum on each wheel is to be made of such a length that the line of contact on each side of the
pitch point (i.e. the path of approach and the path of recess) has half the maximum possible length, therefore

13
MINIMUM NUMBER OF TEETH ON THE PINION IN ORDER TO AVOID INTERFERENCE

8. Determine the minimum number of teeth required on a pinion, in order to avoid interference
which is to gear with, 1. a wheel to give a gear ratio of 3 to 1 ; and 2. an equal wheel. The
pressure angle is 20° and a standard addendum of 1 module for the wheel may be assumed.

Solution. Given : G = T / t = 3 ; φ = 20° ; AW = 1 module

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9. A pair of spur gears with in volute teeth is to give a gear ratio of 4 : 1. The arc of approach is
not to be less than the circular pitch and smaller wheel is the driver. The angle of pressure is
14.5°. Find : 1. the least number of teeth that can be used on each wheel, and 2. The addendum
of the wheel in terms of the circular pitch ?

10. A pair of in volute spur gears with 16° pressure angle and pitch of module 6 mm is in mesh.
The number of teeth on pinion is 16 and its rotational speed is 240 r.p.m. When the gear ratio
is 1.75, find in order that the interference is just avoided; 1. The addenda on pinion and gear
wheel; 2. The length of path of contact; and 3.The maximum velocity of sliding of teeth on
either side of the pitch point.

15
16
11. A pair of 20° full depth involute spur gears having 30 and 50 teeth respectively of module 4
mm are in mesh. The smaller gear rotates at 1000 r.p.m. Determine: 1.Sliding velocities at
engagement and at disengagement of pair of a teeth, and 2.contact ratio.

17
12. Two gear wheels mesh externally and are to give a velocity ratio of 3 to 1. The teeth are of
in volute form; module = 6 mm, addendum = one module, pressure angle = 20°. The pinion
rotates at 90 r.p.m. Determine : 1. The number of teeth on the pinion to avoid interference on it
and the corresponding number of teeth on the wheel, 2. The length of path and arc of contact,
3.The number of pairs of teeth in contact, and 4. The maximum velocity of sliding. .[May/June-
12,14]

18
19
Minimum Number of Teeth on a Pinion for Involute Rack in Order to Avoid Interference
13. A pinion of 20 in volute 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.

20
14. Two unequal gears of involute profile are to give required gear ratio. Derive an expression
for the minimum number of teeth required for the PINION in order to avoid interference.
[May/June-12] [Nov 16]
We have already discussed in the previous article that 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
points 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 = m.t / 2
G = Gear ratio = T / t = R / r
φ = Pressure angle or angle of obliquity

∴Limiting radius of the pinion addendum circle,

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. We know that the addendum of
the pinion
= O 1N – O 1P

21
This equation gives the minimum number of teeth required on the pinion in order to avoid interference.
15. Prove that the maximum length of arc of contact between a pair of gear tooth to avoid
interference is (r+R) tanφ. [Nov 16]
 When interference is just avoided, the maximum length of path of contact is MN when the
maximum addendum circles for pinion and wheel pass through the points of tangency N and M
respectively. In such a case,
Maximum length of path of approach,
MP = r sin φ
and maximum length of path of recess,
PN = R sin φ
∴ Maximum length of path of contact,

16. With the help of a neatly drawn sketch of a spur gear, explain elaborately the nomenclature
of gears. [May/June-13 & 16]

1. Pitch circle: It is an imaginary circle which by pure rolling action, would give the same motion as
the actual gear.

22
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.
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. It is usually denoted by φ.
The standard pressure angles are 12 14 ° and 20°.
6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth.
7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
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 root
circle.
Note: Root circle diameter = Pitch circle diameter × cos φ, where φ is the pressure angle.
10. Circular pitch. It is the distance measured on the circumference of the pitch circle from a point
of one tooth to the corresponding point on the next tooth. It is usually denoted by pc.
Mathematically,
Circular pitch, pc = π D/T
where D = Diameter of the pitch circle, and
T = Number of teeth on the wheel.
A little consideration will show that the two gears will mesh together correctly, if the two wheels have
the same circular pitch.
11. Diametral pitch. It is the ratio of number of teeth to the pitch circle diameter in millimeters.
12. Module. It is the ratio of the pitch circle diameter in millimeters to the number of teeth. It is
usually denoted by m. mathematically,
Module, m = D /T
13. Clearance. It is the 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.
14. Total depth. It is the radial distance between the addendum and the dedendum circles of
a gear. It is equal to the sum of the addendum and dedendum.
15. 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.
16. Tooth thickness. It is the width of the tooth measured along the pitch circle.
17. Tooth space. It is the width of space between the two adjacent teeth measured along the pitch
circle.
18. 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.
19. Face of tooth. It is the surface of the gear tooth above the pitch surface.
20. Flank of tooth. It is the surface of the gear tooth below the pitch surface.
21. Top land. It is the surface of the top of the tooth.
22. Face width. It is the width of the gear tooth measured parallel to its axis.
23. Profile. It is the curve formed by the face and flank of the tooth.
24. Fillet radius. It is the radius that connects the root circle to the profile of the tooth.
25. Path of contact. It is the path traced by the point of contact of two teeth from the beginning to
the end of engagement.
26. 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.

23
 27. Arc of contact. It is the path traced by a point on the pitch circle from the beginning to the end
of engagement of a given pair of teeth. The arc of contact consists of two parts, i.e.
(a) Arc of approach. It is the portion of the path of contact from the beginning of the engagement
to the pitch point.
(b) Arc of recess. It is the portion of the path of contact from the pitch point to the end of the
engagement of a pair of teeth.

17. State and prove the law of gearing. Show that the involute curves as the profiles of mating
gears satisfy the law of gearing. [Nov/Dec-12]

Consider the portions of the two teeth, one on the wheel 1 (or pinion) and the other on the wheel 2, as
shown by thick line curves in Fig. Let the two teeth come in contact at point Q, and the wheels rotate in
the directions as shown in the figure. Let T T be the common tangent and MN be the common normal to
the curves at the point of contact Q. From the centres O1 and O2, draw O1M and O2N perpendicular to
MN. A little consideration will show that the point Q moves in the direction QC, when considered as a point
on wheel 1, and in the direction QD when considered as a point on wheel 2.Let v1 and v2 be the velocities
of the point Q on the wheels1 and 2 respectively. If the teeth are to remain in contact, then the
components of these velocities along the common normal MN must be equal.

From above, we see that the angular velocity ratio is inversely proportional to the ratio of the distances of
the point P from the centres O1 and O2, or the common normal to the two surfaces at the point of contact
Q intersects the line of centres at point P which divides the centre distance inversely as the ratio of
angular velocities. Therefore in order to have a constant angular velocity ratio for all positions of the
wheels, the point P must be the fixed point (called pitch point) for the two wheels. In other words, the
common normal at the point of contact between a pair of teeth must always pass through the pitch point.
This is the fundamental condition which must be satisfied while designing the profiles for the teeth of gear
wheels. It is also known as law of gearing.

24
.
18. A compound gear train using spur gears is required to give a total reduction ratio of 250 to
1 rpm in four steps. The modules of the gears are 5mm for the first step, 7 mm for the second ,
10mm for the third and 16 mm for the fourth
I. Arrive at the individual speed ratios, if a tolerance of ±0.2% is allowed in total reduction
ratio.
II. Find the number of teeth of all gears, if the minimum number of teeth for any pinion is
20.
III. Find the pitch circle diameters of all gears and the center distance.
IV. Sketch the line diagram showing the gear train. [Nov/dec’12]

25
19. An epicyclic gear train as shown below the input S has 24 teeth. Gear P and C constitute a
compound planet having 30 and 18 teeth respectively. If all the gears are of same pitch, find
the speed ratio of gear train assuming A to be fixed. [May/june’13]

20. Explain the various pitches of helical gears with sketch. [Nov/Dec-13]
A helical gear has teeth in the form of helix around the gear. Two such gears may be used to connect
two parallel shafts in place of 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 a high efficiency of transmission.
We have already discussed that the helical gears may be of single helical type or double helical type. In
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.
1. Normal pitch: It is the distance between similar faces of adjacent teeth, along a helix on
26
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
circular pitch,

21. An epicyclic gear consists of three gears A, B and C as shown in Fig.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 centre of A at 18 r.p.m.. If the gear A is fixed,
determine the speed of gears B and C. [Nov/Dec-13][May/June-17]

Speed of gear C:

We know that the

speed of the arm
is 18 r.p.m. therefore,

y = 18 r.p.m. and the gear A is fixed, therefore

27
Speed of gear B:

Let dA, dB and dC be the pitch circle diameters of gears A, B and C respectively. Therefore,
from the geometry of Fig

22. Write short notes on speed ratio of a planetary gear train? [Nov/Dec-13]
 The axes of the shafts, over which the gears are mounted, may move relative to a fixed axis. A
simple epicyclic gear train is shown in Fig, where 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 Up on 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 are known as epicyclic gear trains (epi. means upon and cyclic means
around). The epicyclic gear trains may be simple or compound.

23. Two 10 mm module 20° pressure angle spur gears have addendum equal to one module.
The pinion has 20 teeth and the gear 40 teeth. Determine whether interference will occur or
not. If occurs, to what valve should the pressure angle be changed to eliminate
interference? [May/June-2014]
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24. Derive an expression to determine the length of path of contact between two spur gears of
different size. [May/June-2014]
 Consider a pinion driving the wheel as shown in Fig. When the pinion rotates in 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 (outer end of the tooth face on the
pinion or on the flank near the base circle of wheel). MN is the common normal at the point of
contacts and the common tangent to the base circles. The point K is the intersection of the
addendum circle of wheel and the common tangent. The point L is the intersection of the
addendum circle of pinion and common tangent.

 The length of path of contact is the length of common normal cutoff by the addendum circles of the
wheel and the pinion. Thus the length of 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 path of approach and
the part of the path of contact PL is known as path of recess.

29
25. Briefly explain the sub-classification of compound gear train with neat sketches.
[May/June-2014]
Compound gear train:
 In compound gear trains at least one pair of gears is rigidly mounted on a same shaft, thus that
pair has the same numbers of revolution. They are widely used in textile machines such as drafting
and twisting gearing and head stock gearing.

REVERTED GEAR TRAIN:

 In a reverted gear train, the first and the last gears have the same axis of rotation .If these two
gears are mounted on the same shaft, one of them must be loosely mounted. They find
applications in epicyclic gear trains. They are also used in clocks and machine tools.

30
EPICYCLIC/ PLANETARY GEAR TRAIN:
 Epicyclic gear train is the one in which the axes of some of the gears have motion. The said
gear(s) would be revolving about external axis or axes. Whereas in other gear trains, the axes
of all the gears do not have motion, only the gears rotate on their axes. Planetary gear trains
are often employed to make more compact gear reducer (large speed reduction in a small
volume) compared to other gear trains. Multiple kinematic combinations (multiple inputs) are
possible with planetary gear trains. Since few gears are revolving around, the bearings are
subjected to high loads; requiring constant lubrication. Hence, planetary gears are placed in box
with lubricants, sometimes in a sealed box inaccessible to maintenance crew. Their design and
manufacturing is complex and require a very high degree of balance.
 An epicyclic gear train with one degree of freedom is shown in Fig. The sun gear A is grounded.
In other words, it is held stationary. The arm/lever is pivoted on the axis of gear A and on its
other end it carries a planetary gear B. The gear B is meshing with the sun gear A. As the arm
rotates, the planetary gear B revolves around the periphery of the gear A and also rotates on its
axis since it is meshing with the sun gear A. The gear B is the output gear. Since the sun gear is
grounded, the gear B gets its input only from the rotation of arm. This is called ‘one degree of
freedom’.

26. Explain the Classification of Toothed Wheels?

 The gears or toothed wheels may be classified as follows :

1. According to the position of axes of the shafts. The axes of the two shafts between which the motion is
to be transmitted, may be
(a) Parallel,
(b) Intersecting, and
(c) Non-intersecting and non-parallel.
Spur gears: These gears have teeth parallel to the axis of the wheel.
Helical gearing: in which the teeth are inclined to the axis. The double helical gears are known as
herringbone gears.

 The two non-parallel or intersecting, but coplanar shafts connected by gears .These gears are
called bevel gears. The bevel gears, like spur gears, may also have their teeth inclined to the face
of the bevel, in which case they are known as helical bevel gears. The two non-intersecting and
non-parallel i.e. non-coplanar shaft connected by gears. These gears are called skew bevel gears
or spiral gear. This type of gearing also has a line contact, the rotation of which about the axes
generates the two pitch surfaces known as hyperboloids.

31
 (a) When equal bevel gears (having equal teeth) connect two shafts whose axes are mutually
perpendicular, then the bevel gears are known as miters.
(b) A hyperboloid is the solid formed by revolving a straight line about an axis (not in the same plane),
such that every point on the line remains at a constant distance from the axis.
(c) The worm gearing is essentially a form of spiral gearing in which the shafts are usually at right angles.

27. 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 addenda on pinion and gear
wheels are equal to one module, find the
(i) Contact ratio
(ii) Angle of action of the pinion and the gear wheel
(iii) Ratio of the .sliding to rolling velocity at beginning of the contact, pitch point and end of
contact.[Nov/Dec 14] .[Apl/May 14]

32
28. In the .epicyclic gear train shown in Fig the compound wheels A and B as well as internal
wheels C and D rotate independently about the axis 0. The wheels E and F rotate on the pins
fixed to the arm a. All the wheels are of the same module. The number of teeth on the wheels
are TA = 52 , TB = 56 , TE = TF = 36 . Determine:
(1) The speed of C if the wheel D fixed and arm a rotates at 200 rpm clockwise.
(2) The speed of .C, if the wheel D rotates at 200 rpm counter clockwise and the arm a
rotates 20 rpm counter clockwise. .[Nov/Dec 14]

33
34
GEAR TRAINS: R.S.KHURMI
29. 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 r.p.m. in the anticlockwise direction about the centre of
the gear A which is fixed, determine the speed of gear B. If the gear A instead of being fixed,
makes 300 r.p.m. in the clockwise direction, what will be the speed of gear B

Solution. Given: TA = 36 ; TB = 45 ; NC = 150 r.p.m. (anticlockwise)

The gear train is shown in Fig.

35
30. 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 r.p.m. clockwise.

Solution. Given : TB = 75 ; TC = 30 ; TD = 90 ; NA = 100 r.p.m. (clockwise)

The reverted epicyclic gear train is shown in Fig. First of all, let us find the number of teeth on gear E (TE).
Let dB , dC , dD and dE be the pitch circle diameters of gears B, C, D and E respectively. From the geometry
of the figure,
dB + dE = dC + dD
Since the number of teeth on each gear, for the same module, are proportional to their pitch circle
diameters, therefore
TB + TE = TC + TD
∴ TE = TC + TD – TB = 30 + 90 – 75 = 45
The table of motions is drawn as follows:

36
Compound Epicyclic Gear Train—Sun and Planet Gear
31. An epicyclic gear consists of three gears A, B and C as shown in Fig. 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 centre of A at 18 r.p.m. If the gear A is fixed,
determine the speed of gears B and C. [May/June-17]
Solution. Given : TA = 72 ; TC = 32 ; Speed of arm EF = 18 r.p.m.
Considering the relative motion of rotation as shown in Table.

37
32. An epicyclic train of gears is arranged as shown in Fig.13.11. 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.

38
33. 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. (N/D-17)

Solution. Given : TC = 28 ; TD = 26 ; TE = TF = 18

39
40
34. An epycyclic gear train‘sun and planet’ type shown in Fig. the pitch circle diameter of the
internally toothed ring is to be 224 mm and the module 4 mm. When the ring D is stationary,
the spider A, which carries three planet wheels C of equal size, is to make one revolution in the
same sense as the sun wheel B for every five revolutions of the driving spindle carrying the sun
wheel B. Determine suitable numbers of teeth for all the wheels.
Solution. Given : dD = 224 mm ; m = 4 mm ; NA = NB / 5
Let TB , TC and TD be the number of teeth on the sun wheel B, planet wheels C and the internally toothed
ring D.
The table of motions is given below :

We know that when the sun wheel B makes + 5 revolutions, the spider A makes + 1 revolution. Therefore
from the fourth row of the table,
y = + 1 ; and x + y = + 5
∴x=5–y=5–1=4
Since the internally toothed ring D is stationary, therefore from the fourth row of the table,

41
35. 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 r.p.m., find the speed of shaft B.

42
43
36. Fig. 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. [Nov 16]

44
45
37. An internal wheel B with 80 teeth is keyed to a shaft F. A fixed internal wheel C with 82
teeth is concentric with B. A compound wheel D-E gears with the two internal wheels; D has 28
teeth and gears with C while E gears with B. The compound wheels revolve freely on a pin
which projects from a disc keyed to a shaft A co-axial with F. If the wheels have the same pitch
and the shaft A makes
800 r.p.m., what is the speed of the shaft F? Sketch the arrangement.
Solution. Given : TB = 80 ; TC = 82 ; TD = 28 ; NA = 500 r.p.m.
The arrangement is shown in Fig.

46
38. Fig. 13.17 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

47
39. In the gear drive as shown in Fig. the driving shaft A rotates at 300 r.p.m. in the clockwise
direction, when seen from left hand. The shaft B is the driven shaft. The casing C is held
stationary. The wheels E and H are keyed to the central vertical spindle and wheel F can rotate
freely on this spindle. The wheels K and L are rigidly fixed to each other and rotate together
freely on a pin fitted on the underside of F. The wheel L meshes with internal teeth on the
casing C. The numbers of teeth on the different wheels are indicated within brackets in Fig.
Find the number of teeth on wheel C and the speed and direction of rotation of shaft B.
Solution. Given : NA = 300 r.p.m.(clockwise) ;TD = 40 ; TB = 30 ; TF = 50 ; TG = 80 ; TH = 40 ; TK = 20 ;
TL = 30 In the arrangement shown in Fig. the wheels D and G are auxiliary gears and do not form a part
of the epicyclic gear train.

48
49
40. Fig. shows a compound epicyclic gear in which the casing C contains an epicyclic train and
this casing is inside the larger casing D. Determine the velocity ratio of the output shaft B to
the input shaft A when the casing D is held stationary. The number of teeth on various wheels
are as follows: Wheel on A = 80 ; Annular wheel on B = 160 ; Annular wheel on C = 100 ;
Annular wheel on D = 120 ; Small pinion on F = 20 ; Large pinion on F = 66.

50
51
52
41. Fig. 13.24 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 form the
rear axles to which the road wheels are attached. If the propeller shaft rotates at 1000 r.p.m.
and the road wheel attached to axle Q has a speed of 210 r.p.m. while taking a turn, find the
speed of road wheel attached to axle P. (MAY / JUNE 16)

Since the speed of gear B is 200 r.p.m., therefore from the fourth row of the table,
y = 200 ... (i)
Also, the speed of road wheel attached to axle Q or the speed of gear D is 210 r.p.m., therefore from the
fourth row of the table,

y – x = 210 or x = y – 210 = 200 – 210 = – 10

53
∴ Speed of road wheel attached to axle P
= Speed of gear C = x + y
= – 10 + 200 = 190 r.p.m. Ans.
42. With a neat sketch explain the working principle of differential. [Nov/Dec 14]

 Differential gear of an automobile. The differential gear used in the rear drive of an automobile is
shown in Fig. Its function is
 to transmit motion from the engine shaft to the rear driving wheels, and
 To rotate the rear wheels at different speeds while the automobile is taking a turn.

 As long as the automobile is running on a straight path, the rear wheels are driven directly by the
engine and speed of both the wheels is same. But when the automobile is taking a turn, the outer
wheel will run faster than the * inner wheel because at that time the outer rear wheel has to cover
more distance than the inner rear wheel. This is achieved by epicyclic gear train with bevel gears
as shown in Fig. The bevel gear A (known as pinion) is keyed to the propeller shaft driven from the
engine shaft through universal coupling. This gear A drives the gear B (known as crown gear)
which rotates freely on the axle P.

 Two equal gears C and D are mounted on two separate parts P and Q of the rear axles
respectively. These gears, in turn, mesh with equal pinions E and F which can rotate freely on the
spindle provided on the arm attached to gear B. When the automobile runs on a straight path, the
gears C and D must rotate together. These gears are rotated through the spindle on the gear B.
The gears E and F do not rotate on the spindle. But when the automobile is taking a turn, the inner
rear wheel should have lesser speed than the outer rear wheel and due to relative speed of the
inner and outer gears D and C, the gears E and F start rotating about the spindle axis and at the
same time revolve about the axle axis.

S.S.RATTAN BOOK:
43. Explain the classification of gears?
Gears can be classified according to the relative positions of their shaft axes as follows:
I. Parallel Shafts
 Regardless of the manner of contact, uniform rotary motion between two parallel shafts is
equivalent to the rolling of two cylinders, assuming no slipping. Depending upon the teeth of the
equivalent cylinders i.e. straight or helical, following are the main types of gears to join parallel
shafts:
Spur Gears
54
  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 axes of rotation. This results in sudden application of the load, high impact stresses
and excessive noise at high speeds.
 Further, if the gears have external teeth on the outer surface of the cylinders, the shafts rotate in
the opposite direction .In an internal spur gear, the 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 as shown in.

Spur Rack and Pinion:

 The spur rack and pinion combination converts rotary motion into translatory motion, or vice-
versa. It is used in a lathe in which the rack transmits motion to the saddle.

Helical Gears or 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 engagement, contact occurs only at the point of 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 gears can be used at higher velocities than the spur gears and have greater load-
carrying capacity.
 Helical gears have the disadvantage of having end thrust as there is a force component along the
gear axis. The bearings and the assemblies mounting the helical gears must be able to withstand
thrust loads
Double-helical and Herringbone Gears:
 A double-helical gear is equivalent to a pair of helical gears secured together, one having a right-
hand helix and the other a left-hand helix. The teeth of the two rows are separated by a groove
used for tool run out. Axial thrust which occurs in case of single-helical gears is eliminated in
55
 double-helical gears. This is because the axial thrusts of the two rows of teeth cancel each other
out. These can be run at high speeds with less noise and vibrations.
 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 herring-bone gear

2. Intersecting Shafts
 Kinematically, the motion between two intersecting shafts is equivalent to the rolling of two cones,
assuming no slipping. The gears, in general, are known as bevel gears.
 When teeth formed on the cones are straight, the gears are known as straight bevel and 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 (Fig). Gears of the same size and connecting two shafts at right angle to each other are
known as mitre gears. At the beginning of engagement, straight bevel gears make the line contact
similar to spur gears. There can also be internal bevel gears analogous to internal spur 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 (Fig). They are smoother in action and quieter than straight tooth
bevels as there is gradual load application 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.

Zerol Bevel Gears

 Spiral bevel gears with curved teeth but with a zero degree spiral angle are known as zerol bevel
gears (Fig). 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 quiter in action than the straight
bevel type as the teeth are curved.

56
3. Skew Shafts
 In case of parallel and intersecting shafts, a uniform rotary motion is possible by pure rolling
contact. But in case of skew (non-parallel, non-intersecting) shafts, this is not possible.
Hypoid Gears
 As mentioned earlier, hypoid gears are approximations of hyperboloids though they look like spiral
gears Fig. A hypoid pinion is larger and stronger than a spiral bevel pinion. A hypoid pair has a
quiet and smooth action. Moreover, the shafts can pass each other so that bearings can be used on
both sides of the gear and the pinion

44. Explain the LAW OF GEARING.

 The law of gearing states the condition which must be fulfilled by the gear tooth profiles to
maintain a constant angular velocity ratio between two gears.

A point C on the tooth profile of gear 1 is in contact with a point D on the tooth profile of gear 2. The two
curves in contact at point C or D must have a common normal at the point. Let it be n – n.
Let ω1 = instantaneous angular velocity of gear 1 (clockwise)
ω2 = instantaneous angular velocity of gear 2 (counter-clockwise)
Vc = linear velocity of C
Vd = linear velocity of D
Vc = ω1. AC in a direction perpendicular to AC
Vd = ω2. BD in a direction perpendicular to BD
Now, if the curved surfaces of the teeth of two gears are to remain in contact, one surface may slide
relative to the other along the common tangent t – t. The relative motion between the surfaces along the
common normal n – n must be zero to avoid the separation, or the penetration of the two teeth into each
other
Component of Vc along n – n = Vc cos α
Component of Vd along n – n = Vd cos β
Relative motion along n – n = Vc cos α - Vd cos β

57
  Thus, it is seen that the centre line AB is divided at P by the common normal in the inverse ratio of
the angular velocities of the two gears. If it is desired that the angular velocities of two gears
remain constant, the common normal at the point of contact of the two teeth should always pass
through a fixed point P which divides the line of centers in the inverse ratio of angular velocities of
two gears.
 As seen earlier, P is also the point of contact of two pitch circles which divides the line of centers in
the inverse ratio of the angular velocities of the two circles and is the pitch point.
 Thus, for constant angular velocity ratio of the two gears, the common normal at the point of
contact of the two mating teeth must pass through the pitch point.

 VELOCITY OF SLIDING
 If the curved surfaces of the two teeth of the gears 1 and 2 are to remain in contact, one can have
a sliding motion relative to the other along the common tangent t – t at C or D

45. Explain the FORMS OF TEETH.

1. Cycloidal profile teeth
2. Involute profile teeth
1. Cycloidal profile teeth:
 A cycloid is the locus of a point on the circumference of a circle that rolls without slipping on a fixed
straight line.
 An epicycloid is the locus of a point on the circumference of a circle that rolls without slipping on
the circumference of another circle.
 A hypocycloid is the locus of a point on the circumference of a circle that rolls without slipping
inside the circumference of another circle.

58
 The formation of a cycloidal tooth has been shown in Fig. A circle H rolls inside another circle APB
(pitch circle). At the start, the point of contact of the two circles is at A. As the circle H rolls inside
the pitch circle, the locus of the point A on the circle H traces the path ALP which is a hypocycloid.
A small portion of this curve near the pitch circle is used for the flank of the tooth.
 A property of the hypocycloid is that at any instant, the line joining the generating point (A) with
the point of contact of the two circles is normal to the hypocycloid, e.g. when the circle H touches
the pitch circle at D, the point A is at C and CD is normal to the hypocycloid ALP.
 Also, Arc AD = Arc CD (on circle H)
 In the same way, if the circle E rolls outside the pitch circle, starting from P, an epicycloid PFB is
obtained. Similar to the property of a hypocycloid, the line joining the generating point with the
point of contact of the two circles is a normal to the epicycloid, e.g. when the circle E touches the
pitch circle at K, the point P is at G and GK is normal to the epicycloid PFB.

2. Involute profile teeth:

 An involute is defined as the locus of a point on a straight line which rolls with-out slipping on the
circumference of a circle. Also, it is the path traced out by the end of a piece of taut cord being
unwound from the circumference of a circle. The circle on which the straight line rolls or from which
the cord is unwound is known as the base circle.
 Figure shows an involute generated by a line rolling over the circumference of a base circle with
centre at 0. At the start, the tracing point is at A. As the line rolls on the circumference of the
circle, the path ABC traced out by the point A is the involute.
 Note that as D can be regarded as the instantaneous centre of rotation of B, the motion of B is
perpendicular to BD. Since BD is tangent to the base circle, the normal to the involute is a tangent
to the base circle.
 A short length EF of the involute drawn from A can be utilized to make the profile of an involute
tooth. The other side HJ of the tooth has been taken from the involute drawn from G in the reverse
direction. The profile of an involute tooth is made up of a single curve, and teeth, usually, are
termed as single curve teeth.
59
  Owing to the ease of standardization and manufacture, and low cost of production, the use of
involute teeth has become universal by entirely superseding the cycloidal shape. Only one cutter or
tool is necessary to manufacture a complete set of interchangeable gears. The cutter is in the form
of a rack as all gears will gear with their corresponding rack. Moreover, the cutters of this form can
be made to a higher degree of accuracy as the teeth of an involute rack are straight.

46. Explain the INTERCHANGEABLE GEARS.

 The gears are interchangeable if they are standard ones. It is always a matter of convenience to
have gears of standard dimensions which can be replaced easily when they are worn out. The
gears are interchangeable if they have
The same module
The same pressure angle
The same addendums and dedendums and
The same thickness
 A tooth system which relates the various parameters of gears such as pressure angle, addendum,
dedendum, tooth thickness, working depth, etc. to attain interchangeability of the gears of all tooth
numbers, but of the same pressure angle and pitch is said to be a standard system. Usually, the
standard cutters are available for their manufacture.
 In Table, tooth proportions for completely interchangeable gears are given. They can be used for
operation on standard centre distances. 14.5° pressure angle system has become obsolete now as
the size of the gears used to be larger as compared to the gears with higher angles.

47. Explain the NONSTANDARD GEARS.

 The term nonstandard gears apply to such gears which are modified by changing some standard
parameters like pressure angle, addendum, tooth depth or centre distance. These changes are
made to improve the performance of the gear operation or from economical point of view.
 The recent trend these days is to make the designs of machines as compact as possible to reduce
their size and weight which also results in reduction in the costs. Consider a gear set to have a
velocity ratio of 4:1. If a pinion of 80 mm pitch diameter is selected for the purpose, the pitch
diameter of the gear is 320 mm. Thus, space requirement of gear is 400 mm. Now, if somehow the
pitch diameter of the pinion is reduced by 10 mm, the pitch diameter of the gear is reduced by 40
mm, and the overall reduction in space is 50 mm. Also, the sizes of other components associated
with the gear set such as shafts, casings and bearings are also reduced. The only way to have a
smaller size of gears is to reduce the number of teeth. However, for a typical type of teeth, it is
observed that if the number of teeth is reduced from a certain number, the problems of
interference, undercutting and contact ratio hamper the smooth running of the gears. Therefore,
the main reason to employ nonstandard gears is to prevent interference and undercutting and to
maintain a reasonable contact ratio.
 It should be remembered that as an involute is generated, its radius of curvature go on becoming
larger and larger, being zero at the base circle. As far as possible, the curve near the base should
be avoided because high stresses are developed in the region of sharp curvature.
 Centre-distance Modifications:
 The number of teeth on a pinion can be reduced from the minimum allowable number by increasing
the centre distance marginally and by changing the tooth proportions and the pressure angle of the
gears. A reduction in the interference and improvement in the contact ratio is brought this way.
The teeth can be generated with rack cutters of standard pressure angles by displacing the pitch
line of the rack from the pitch circle of the gear. This action produces teeth which are thicker than
before.
 Clearance Modifications:

60
  If the clearance between mating teeth is increased to 0.3 m or 0.4 m instead of usual value of 0.25
in to have a larger fillet at the root of the tooth, the fatigue strength of the tooth is increased. This
way some extra depth is available to smoothen the tooth profile. Interchangeability is not lost this
way.
 Addendum Modifications:
 In cases where it is not possible to change the centre distances, modifications can be made to the
addendum. In such cases, there has to be no change in the pitch circles and the pressure angles.
However, the contact region is shifted away from the pinion centre towards the gear centre,
decreasing the approach action and increasing the recess action.

48. Derive the expression for ARC OF CONTACT.

 We have already defined that the arc of contact is the path traced by a point on the pitch circle
from the beginning to the end of engagement of a given pair of teeth. In Fig., 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 arc of recess. The angles
subtended by these arcs at O1 are called angle of approach and angle of recess respectively We
know that the length of the arc of approach (arc GP)

 And the length of the arc of recess (arc PH)

 Since the length of the arc of contact GPH is equal to the sum of the length of arc of approach and
arc of recess, therefore, Length of the arc of contact

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

49. Explain the INTERFERENCE IN INVOLUTE GEARS.

61
  Power transmission through a pair of teeth is along the line of action or the common normal to the
two involutes at the point of contact: The common normal is also a common tangent to the two
base circles and passes through the pitch point. At any instant, the portions of the tooth profiles
which are in contact must be involute so that the line of action does not deviate. If any of the two
surfaces is not involute, the two surfaces would not touch each other tangentially and the
transmission of power would not be proper. Mating of two non-conjugate (non-involute) teeth is
known as interference because the two teeth do not slide properly and thus, rough action and
binding occurs. Owing to non-involute profile, the contacting teeth have different velocities which
can lock the two gears.
 Figure shows two gears in mesh. If pinion is the driver, the line of action will be along EF which is
the common tangent to base circles of the two gears. Let the addendum radius of the wheel be BC
and that of pinion AD. The teeth on the pinion and wheel are engaged at C and are disengaged at
D. Now, if the radius of the addendum circle of the pinion is increased, the point D shifts along PF
towards F and the point D coincides with F when the radius is equal to AF. Any further increase in
the value of this radius will result in shifting the point of contact inside the base circle of the wheel.
Since an involute can exist only outside the base circle, therefore, any profile of teeth inside the
base circle will be of non-involute type. Usually, a radial profile is adopted for this portion. Thus,
the profiles in such a case cannot be tangent to each other and the tip of the pinion would try to
dig out the flank of the tooth of the wheel. Therefore, interference occurs in the mating of two
gears.
 Similarly, if the addendum radius of the wheel is made greater than BE, the tip of the wheel tooth
will be in contact with a portion of the non-involute profile of the pinion tooth for some of the
engagement. The conclusion is that to have no interference of the teeth, the addendum circles of
the wheel and the pinion must intersect the line of action between E and F. The points E and F are
called interference points.
 Note that to avoid interference, the limiting value of addendum of the wheel is GE, whereas that of
pinion it is HF and the latter is clearly greater than the former. Thus, if the addenda of the wheel
and the pinion are to be equal, the addendum circle of the wheel passes through the limiting point
E on the line of action before the addendum circle of the pinion passes through the limiting point F
on the same line. Thus, for equal addenda of the wheel and the pinion, the addendum radius of the
wheel decides whether the interference will occur or not.

50. Explain the UNDERCUTTING?

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  A portion of its dedendum falls inside the base circle. The profile of the tooth inside the base circle
is radial. If the addendum of the mating gear is more than the limiting value, it interferes with the
dedendum of the pinion and the two gears are locked.
 However, if a cutting rack having similar teeth is used to cut the teeth in the pinion, it will remove
that portion of the pinion tooth which would have interfered with the gear as shown in Fig. A gear
having its material removed in this manner is said to be undercut and the process, undercutting. In
pinion with small number of teeth, this can seriously weaken the tooth. However, when the actual
gear meshes with the undercut pinion, no interference occurs. Undercutting will not take place if
the teeth are designed to avoid interference.

51. COMPARISON OF CYCLOIDAL AND INVOLUTE TOOTH FORMS

CYCLOIDAL:
(a) Pressure angle varies from maximum at the beginning of engagement, reduces to zero at
the pitch point and again increases to maximum at the end of engagement resulting in less smooth
running of the gears.
(b) It involves double curve for the teeth, epicycloid and hypocycloid. This complicates the
manufacture.
(c) Owing to difficulty to manufacture these are costlier.
(d) Exact centre-distance is required to transmit a constant velocity ratio.

INVOLUTE:
(a)Pressure angle is constant throughout the engagement of teeth. This results in smooth running
of the gears.
(b)It involves single curve for the teeth resulting in simplicity of manufacturing and of tools.
(c )These are simple to manufacture and thus, are cheaper.
(d)A little variation in the centre distance does not affect the velocity ratio

52. Explain WORM AND WORM GEAR.

 To accomplish large speed reduction in skew shafts, spiral gears with a small driver and a larger
follower are required. Also, the load transmitted through these gears is limited. To transmit a little
higher load than with the usual spiral gears, use of worm and worm gears (throated type) can be
made. Usually, worm and worm gears are used to connect two skew shafts at right angle to each

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 other. The axial length of the worm is increased so that at least one or two threads (teeth)
complete the circle on it .A worm can be a single, double or triple start if one, two or three threads
are traversed on the worm for one tooth advancement of the gear wheel. Figures, show a single
start and a double start worm respectively.

TERMINOLOGY:

(i)Axial Pitch (pa):

 It is the distance between corresponding points on adjacent teeth measured along the direction of
the axis.
(ii)Lead (L):
 The distance by which a helix advances along the axis of the gear for one turnaround is known as
lead.
 In a single helix, the axial pitch is equal to lead, in a double helix, this is one-half the lead, in a
triple helix, one third of lead and so on.
(iii) Lead Angle (A):
 It is the angle at which the teeth are inclined to the normal to the axis of rotation.
(iv)Velocity Ratio:

(v)Centre Distance:

(v)Efficiency:

53. Explain the BEVEL GEARS.

 To have a gear drive between two intersecting shafts, bevel gears are used. Kinematically, bevel
gears are equivalent to rolling cones.

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54. 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 the speed of the driver. What will be
the pitch line velocities?

55. The number of teeth of a spur gear is 30 and it rotates at 200 rpm. What will be its circular
pitch and .ne pitch line velocity if it has a module of 2 mm?

56. The following data relate to two meshing gears:

Velocity ratio = 1 Module = 4 mm, Pressure angle = 20°, Centre distance= 200 mm. Determine
the number of teeth and the base circle radius of the gear wheel.

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57. Two gears in 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 addenda on pinion and gear wheels are equal to one
module, find
(i) The number of pairs of teeth in contact
(ii) The angle of action of the pinion and the gear wheel
(iii) The ratio of the sliding to rolling velocity at
(a) The beginning of contact
(b) The pitch point
(c) The end of contact

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58. Two 20° gears have a module pitch of 4 mm. The number of teeth on gears 1 and 2 are 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

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59. Two 20° involute spur gears mesh externally and give a velocity ratio of 3. Module is 3 mm
and the addendum is equal to 1.1 module. If the pinion rotates at 120 rpm, determine
(i) The minimum number of teeth on each wheel to avoid interference
(ii) The number of pairs of teeth in contact.

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60. 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?

61. Two 20° in volute spur gears have a module of 10 mm. The addendum is one module. The
larger gear has 50 teeth and the pinion 13 teeth. Does the interference occur? If it occurs, to
what value should the pressure angle be changed to eliminate interference?

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62. Following data relate to two meshing in volute gears:
Number of teeth on the gear wheel = 60, Pressure angle = 20°, Gear ratio = 1.5, Speed of the
gear wheel = 100 rpm, Module = 8 mm The addendum on each wheel is such that the path of
approach and the 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.

63. A pinion of 32 in volute teeth and 4 mm module drives a rack. The pressure angle is 20°.
The addendum of both pinion and rack is the same. Determine the maximum permissible value
of the addendum to avoid interference. Also find the number of pairs of teeth in contact.

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