A TECHNICAL REPORT

ON

GEARS AND DIFFERENTIALS

DONE BY

BALOGUN SHEREEFDEEN ILEMOBAYO: 223865

AGRICULTURAL AND ENVIRONMENTAL ENGINEERING

FACULTY OF TECHNOLOGY

JULY 2024
 TABLE OF CONTENT

Chapter 1 Introduction

Chapter 2 Gears
Definition of a Gear
Gear Terminologies
Types of Gear
Parts of Gear
Applications of Gear
Gear Ratio and Calculations

Chapter 3 Differentials
Definition of Differentials
Differential Terminologies
Types of Differentials
Working principle of a differential
Applications of a differential

Chapter 4 Conclusion
 CHAPTER 1 INTRODUCTION

1. Introduction
Gears are ubiquitous in engineering, playing a pivotal role in machines ranging from simple
hand tools to complex industrial systems. Their ability to alter torque, speed, and direction of
motion makes them indispensable in numerous applications. This report delves into the
intricate world of gears, exploring their design, functionality, and significance in different
sectors.
Gears are critical components in mechanical engineering, used to transmit torque and
rotational motion between shafts in various machinery and devices. This report provides a
comprehensive overview of gears, discussing their fundamental principles, types and
applications. Through this exploration, the report aims to elucidate the importance of gears in
modern engineering and highlight the innovations enhancing their performance and reliability.
 CHAPTER 2 GEARS

2.1 Definition of Gears

A gear is a mechanical component consisting of toothed wheels or cylinders that mesh with
each other to transmit rotational motion and torque from one part of a machine to another.
Gears are designed to change the speed, direction, or torque of mechanical energy, depending
on their configuration and the relationship between their teeth. They are integral to various
applications in machinery, vehicles, and devices, facilitating efficient power transmission and
motion control through their precise engagement and rotation.

2.2 Gear Terminologies

Understanding gear terminologies is essential for comprehending their design, function, and
applications. Here are some key terminologies related to gears:
Pitch Circle: The theoretical circle where the pitch diameter of a gear is measured, defining
where gears mesh.

Pitch Diameter: The diameter of the pitch circle where gear teeth engage.

Module (Metric) or Diametral Pitch (Imperial):

• Module: Metric measure of gear tooth size, calculated as the pitch diameter divided by
the number of teeth.
• Diametral Pitch: Imperial measure of gear tooth size, indicating the number of teeth per
inch of pitch diameter.

Pressure Angle: Angle at which the line of action touches the pitch circles of meshing gears,
affecting engagement strength.

Addendum and Dedendum:

• Addendum: Radial distance from the pitch circle to the top of a gear tooth.
• Dedendum: Radial distance from the pitch circle to the bottom of the tooth space.

Face Width: Width of a gear tooth along its face.

Helix Angle (Helical Gears): Angle between gear teeth and the gear axis, influencing smooth
operation and load capacity.

Backlash: Clearance between mating gear teeth, allowing for lubrication and thermal expansion
while affecting precision and noise levels.

Gear Ratio: Ratio of teeth numbers between meshing gears, determining speed and torque
relationships.

Contact Ratio: Ratio of arc of contact length to pitch circle circumference, influencing smooth
operation and load distribution.

Herringbone Gears: Gears with "V"-shaped teeth, eliminating axial thrust and providing
smoother operation than straight-cut gears.

Internal Gears: Gears with teeth cut on the inside, used in planetary systems and speed
reducers.
2.3 Types of Gears

Spur Gears: These gears have straight teeth and are mounted on parallel shafts. They are the
most common type of gear and are used for simple, straightforward power transmission.

Helical Gears: With teeth cut at an angle to the gear axis, helical gears engage more gradually
and smoothly compared to spur gears. They are used in applications requiring high speed and
large power transmission.

Bevel Gears: These gears have teeth cut on an angular cone surface and are used to transmit
motion between intersecting shafts, usually at a 90-degree angle. Variants include straight
bevel gears and spiral bevel gears.
Worm Gears: Consisting of a worm (a screw-like component) and a worm wheel (similar to a
spur gear), worm gears provide high reduction ratios and transmit motion at right angles. They
are known for their non-reversible movement and compact design.

Rack and Pinion: This gear system includes a cylindrical gear (pinion) and a linear gear (rack). It
converts rotational motion into linear motion and is commonly used in steering mechanisms
and linear actuators.
Herringbone Gears: Similar to helical gears but with a V-shaped tooth pattern, herringbone
gears eliminate axial thrust and provide smooth operation. They are used in heavy machinery
where high load capacity is required.

Hypoid Gears: These gears are similar to spiral bevel gears but with their axes offset. They are
used in automotive differentials to allow the driveshaft to be lower than the input shaft of the
wheel.
Planetary Gears (Epicyclic Gears): This system consists of a central sun gear, planet gears that
rotate around the sun gear, and an outer ring gear. It is used in automatic transmissions and
other applications requiring compact, high-torque, and variable-speed drives.

Internal Gears: These gears have teeth cut on the inside surface of a cylindrical or conical gear.
They are used in planetary gear systems and compact gear trains where space is limited.
2.4 Parts of gear
Gears consist of several key parts, each contributing to their function and performance. Here
are the main parts of a gear:

Teeth are the protrusions along the edge of the gear wheel that engage with the teeth of
another gear or a rack. They determine how gears mesh and transfer mechanical energy.

The Pitch Circle, also known as the pitch line or reference circle, is an imaginary circle defining
the point of contact between meshing gears. It is used to calculate the gear's dimensions and
relationships.

Pitch Diameter is the actual diameter of the pitch circle where gear teeth engage.

Addendum is the radial distance from the pitch circle to the top of a gear tooth, influencing
engagement and strength.

Dedendum is the radial distance from the pitch circle to the bottom of the tooth space, defining
tooth depth and clearance.

Face is the surface of the gear tooth extending from its tip to the base of the tooth space,
where contact occurs with the mating gear.

Root Diameter is the diameter of the gear at the bottom of the tooth spaces, smaller than the
pitch diameter and used in calculations.

Hub is the central part of the gear where it mounts onto a shaft, providing support and torque
transmission.

Keyway is a slot in the hub to accommodate a key, preventing independent rotation and
ensuring a solid connection to the shaft.

Bore is the central hole through the gear hub where the shaft is inserted, allowing rotation
along with the shaft.

Gear Face is the broad surface of the gear wheel where teeth are located, making contact with
the mating gear or rack during operation.
2.5 Application of Gears

In the automotive sector, gears are crucial in transmissions, enabling smooth gear shifts for
optimal vehicle performance and fuel efficiency. They also play a vital role in differentials,
facilitating stable cornering and traction control by distributing power to the wheels at varying
speeds.

Industrial machinery relies on gears for tasks such as driving conveyor belts in manufacturing
facilities, powering machine tools like lathes and milling machines, and controlling packaging
systems for efficient product handling.

In power generation, gears are integral to wind turbines, converting the rotational motion of
turbine blades into electrical power. They also contribute to hydroelectric plants by transferring
energy from water turbines to generators.

Within aerospace, gears drive essential systems such as aircraft engines, transmitting power to
components like fuel pumps and flight control systems. They ensure precise control of flight
surfaces and auxiliary functions.

Consumer electronics benefit from gears in timekeeping mechanisms for clocks and watches,
as well as in cameras for controlling focus, aperture, and film advance.
Medical equipment utilizes gears in diagnostic imaging machines like MRI and CT scanners,
enabling precise positioning and movement of imaging components. Gears also play a role in
surgical robotics, facilitating accurate instrument control during procedures.

In the marine industry, gears are pivotal in propulsion systems for ships, transmitting power
from engines to propellers to control speed and direction. They also power winches and cranes
for lifting and maneuvering heavy loads.

Gears contribute significantly to renewable energy applications, such as in solar tracking

systems that adjust solar panel orientation for optimal sunlight exposure throughout the day.
They also aid in wave and tidal energy converters by transforming irregular wave and tidal
motion into rotational energy for electricity generation.

Across these diverse fields, gears ensure efficiency, precision, and reliability in mechanical
systems, demonstrating their critical importance in modern technology and industrial processes.

2.6 Gear Ratio

Gear ratio refers to the ratio of the number of teeth between two meshing gears. It determines
the relationship between the rotational speeds and torques of the gears involved in a gear pair
or gear train.

The gear ratio is calculated based on the following principles:

• For Spur Gears: The gear ratio is determined by dividing the number of teeth on the
driven gear (or output gear) by the number of teeth on the driving gear (or input gear).
• For Worm Gears: The gear ratio is calculated by dividing the number of threads on the
worm (the screw-like gear) by the number of teeth on the worm wheel (the gear
meshed with the worm).

Gear ratio affects:

• Speed: A higher gear ratio (more teeth on the driving gear relative to the driven gear)
results in reduced speed at the output with increased torque.
• Torque: Conversely, a lower gear ratio (fewer teeth on the driving gear relative to the
driven gear) increases speed at the output while reducing torque.

In practical applications, gear ratio selection depends on the desired output speed and torque
requirements for a given mechanical system. Gear trains, consisting of multiple gears meshed
together, allow for complex combinations of gear ratios to achieve specific performance
characteristics such as speed reduction, torque multiplication, or maintaining consistent
rotational speed.
 CHAPTER 3 DIFFERENTIALS

3.1 Definition of Differentials

Differentials are mechanical devices used in vehicles and machinery to distribute power
between two or more shafts that need to rotate at different speeds. They allow for smooth
turning of vehicles by enabling wheels to rotate at varying speeds during turns while
maintaining power delivery from the engine.

In essence, differentials are gear assemblies that consist of a set of bevel gears housed within a
casing. They are crucial components in automotive drivetrains, particularly in rear-wheel and
all-wheel-drive vehicles, where they distribute torque from the engine to the wheels efficiently.
Differentials also play a role in ensuring traction and stability by allowing wheels to rotate at
different speeds, such as when navigating corners or uneven terrain.

Overall, differentials facilitate efficient power transmission while accommodating variations in

rotational speeds between connected shafts or wheels, making them indispensable in modern
vehicle design and other mechanical applications.

3.2 Differentials Terminologies

Differential Gear: The set of gears inside the differential housing that allows the two output
shafts (axle shafts) to rotate at different speeds while receiving power from the input shaft
(driveshaft).

Spider Gears: Also known as side gears or pinion gears, these are the small gears that mesh
with the differential gear and allow the differential to operate. They are located at the ends of
the axle shafts.

Ring Gear: A large gear attached to the differential case that meshes with the pinion gear
(driveshaft gear) to transfer torque from the driveshaft to the differential gear and
subsequently to the axle shafts.

Pinion Gear: The small gear on the driveshaft that meshes with the ring gear. It transfers
rotational motion and torque from the driveshaft to the ring gear and differential gear.
Axle Shafts: The shafts connected to the differential gears on each side of the differential
housing. They transmit torque from the differential to the wheels.

Limited-Slip Differential (LSD): A type of differential that limits the speed difference between
the two output shafts, providing better traction and stability by transferring power to the wheel
with more grip when one wheel loses traction.

Open Differential: The standard differential design where power is distributed equally
between the two output shafts. It allows wheels to spin independently, which can result in
wheel slip in low-traction conditions.

Locking Differential: A differential that can be mechanically locked to ensure equal torque
distribution to both output shafts, enhancing traction in off-road and low-traction conditions.

Traction Control System (TCS): An electronic system that uses sensors to detect wheel slip and
applies brake or engine torque control to specific wheels to maintain traction and stability.

Differential Housing: The casing that encloses the differential gears and components,
providing support and protection while allowing for lubrication and heat dissipation.

Differential Ratio: The gear ratio between the ring gear and the pinion gear, determining the
speed and torque characteristics of the differential and the vehicle's drivetrain.

3.3 Types of Differentials

Open Differential:

• The most common type.

• Allows the wheels to rotate at different speeds during turns.
• Distributes torque equally to both wheels.
Limited-Slip Differential (LSD):

• Limits the speed difference between the two wheels.

• Provides better traction and stability compared to an open differential.
• Ideal for high-performance vehicles and off-road applications.

Locking Differential:

• Can be mechanically locked to ensure both wheels receive equal torque.

• Provides maximum traction in challenging off-road conditions.
• Typically used in 4WD and off-road vehicles.
Torsen (Torque-Sensing) Differential:

• Uses worm gears to distribute torque based on traction conditions.

• Automatically adjusts torque distribution between wheels.
• Provides improved traction and handling performance.

Electronic Differential (eDiff):

• Uses electronic controls to vary torque distribution between wheels.

• Provides precise control and adjustment of torque based on driving conditions.
• Commonly found in modern sports cars and performance vehicles.
Spool Differential:

• Essentially locks both wheels together.

• Provides maximum traction at all times.
• Mostly used in racing and high-performance applications
 3.4 Working Principle of a differential

The differential is a crucial component in vehicles that allows the wheels on the same axle to
rotate at different speeds while receiving power from the engine. Its primary function is to
compensate for differences in wheel speed during turns, ensuring smooth and efficient
operation. Here's the working principle of a differential:

1. Power Input: The differential receives rotational power from the engine through the
driveshaft. The driveshaft is connected to a pinion gear, which meshes with a ring gear
attached to the differential case.
2. Distribution of Power: The ring gear transfers the rotational power to the differential
gears inside the differential housing. These gears include the spider gears (or side
gears), which are typically mounted on the differential carrier.
3. Axle Shafts Connection: The differential gears are connected to the axle shafts that
extend to the wheels on each side of the vehicle. As the differential gears rotate, they
transmit torque to the axle shafts.
4. Differentiation of Wheel Speeds: When the vehicle makes a turn, the outer wheel
travels a longer path than the inner wheel. This difference in distance would cause the
wheels to rotate at different speeds if they were directly connected without a
differential.
5. Allowing Differential Action: The differential allows for this speed differentiation by
allowing the axle shafts to rotate at different speeds. This is facilitated by the ability of
the spider gears to rotate independently on the differential carrier.
6. Equalizing Torque: In an open differential, torque is distributed equally to both wheels.
When one wheel encounters less resistance (such as when turning or on slippery
surfaces), it receives more torque, while the other wheel receives less. This helps
maintain traction and stability.
7. Specialized Differentials: Variations like limited-slip differentials and locking
differentials modify this basic principle to enhance traction and stability. Limited-slip
differentials use friction or mechanical means to limit speed differences between
wheels, while locking differentials mechanically lock both wheels together when
traction is needed.

In essence, the differential's function is to allow wheels to rotate at different speeds while
transmitting power from the engine, ensuring efficient operation and optimal traction under
various driving conditions. This capability is critical for vehicle dynamics, particularly during
turns and when navigating uneven terrain.
 CHAPTER 4

CONCLUSION

In conclusion, gears and differentials play a fundamental role in the mechanics of modern
machinery and vehicles. Gears, with their diverse types and applications, are essential for
efficiently transmitting power, adjusting speeds, and converting motion. Their versatility is
evident across various industries, from automotive and aerospace to consumer electronics and
renewable energy. The precise engineering and design of gears ensure the smooth and reliable
operation of countless mechanical systems, contributing to advancements in technology and
industrial processes.

Differentials, on the other hand, are critical components in automotive drivetrains, providing
the necessary functionality for vehicles to navigate turns and uneven terrain with stability and
traction. The different types of differentials, including open, limited-slip, locking, electronic, and
torque vectoring differentials, each offer unique advantages tailored to specific performance
requirements. Understanding the terminologies, working principles, and applications of
differentials enhances our ability to design and maintain vehicles that perform optimally under
various conditions.

Overall, the study of gears and differentials underscores the importance of these mechanical
components in achieving efficient, precise, and reliable operation in a wide range of
applications. Their continued development and innovation will undoubtedly drive further
advancements in engineering and technology, shaping the future of mechanical systems and
their applications in numerous fields.