MENG 306
Kinematics and Dynamics of Mechanical Systems
Gears
Dr. Ahmed Asker
Rolling Cylinders
The simplest means of transferring rotary motion from one shaft
to another is a pair of rolling cylinders.
Provided that sufficient friction is available at the rolling
interface, this mechanism will work quite well.
There will be no slip between the cylinders until the maximum
available frictional force at the joint is exceeded by the demands
of torque transfer.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 2
Rolling Cylinders
The angular velocity ratio between two meshing gears remains
constant throughout the mesh
Conceptually, teeth of any shape will prevent gross slip.
Old water-powered mills and windmills used wooden gears.
𝑟𝑖𝑛
𝑣 → 𝜔𝑜𝑢𝑡 = 𝜔𝑖𝑛 Input
𝑟𝑜𝑢𝑡
𝑃𝑜𝑢𝑡 = 𝑃𝑖𝑛 → 𝑇𝑜𝑢𝑡 𝜔𝑜𝑢𝑡 = 𝑇𝑖𝑛 𝜔𝑖𝑛 ω𝑖𝑛 𝑟𝑖𝑛 = ω𝑜𝑢𝑡 𝑟𝑜𝑢𝑡
𝑇𝑖𝑛 𝜔𝑜𝑢𝑡 𝑟𝑖𝑛
= = 𝑣 = ω𝑟
𝑇𝑜𝑢𝑡 𝜔𝑖𝑛 𝑟𝑜𝑢𝑡
Output
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 3
Rolling Cylinders
Gear analysis is based on rolling cylinders
External gears rotate in opposite directions
Internal gears rotate in same direction
Two gears together are called a gearset
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 4
Gear Types
Spur Gears
Helical Gears (open or crossed)
Herringbone Gears
Worm Gears
Rack and Pinion
Bevel Gears
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 5
Spur Gears
Straight teeth
Noisy since all of the tooth
contacts at one time
Low Cost
High efficiency (98-99%)
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 6
Helical Gears
Inclined teeth to smooth contact
Axis can be parallel or crossed
Has a thrust force
Efficiency of 96-98% for parallel
and 50-90% for crossed
Crossed axis helical gears
Parallel axis helical gears
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 7
Herringbone Gears
Eliminate the thrust force
95% efficient
Very expensive
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 8
Rack and Pinion
Generates linear motion
Teeth are straight (one way to cut a involute form)
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 9
Worm Gears
Worm gear has one or two teeth
High gear ratio (up to 50)
Impossible to back drive
40-85% efficient
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 10
Bevel Gears
Based on rolling cones
Need to share a common tip
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 11
Other Gear Types
Noncircular gears – give a different velocity ratio at different
angles
Synchronous belts and sprockets – like pulleys (98% efficient)
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 12
Fundamental Law of Gearing
Fundamental Law of Gearing require that
the angular velocity ratio between the
gears of a gearset should remains
constant throughout the mesh.
The line of action will intersect the line
of centers O-O at some point P.
The angular-velocity ratio between the
two arms is inversely proportional to
their radii to the point P.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 13
Involute Tooth Shape
Shape of the gear tooth is the involute curve.
Shape you get by unwrapping a string from
around a circle
Allows the fundamental law of gearing to
be followed even if center distance is not
maintained
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 14
Fundamental Law of Gearing
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 15
Fundamental Law of Gearing
The common normal of the tooth profiles, at all contact points
within the mesh, must always pass through a fixed point on the
line of centers, called the pitch point
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 16
Contact Geometry
Pressure angle (𝜙): is the angle between the axis of transmission
or line of action (common normal) and the direction of velocity at
the pitch point, i.e., angle between force and motion.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 17
Change in Center Distance
With the involute tooth form, the fundamental law of gearing is
followed, even if the center distance changes.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 18
Gear Tooth Nomenclature
𝜋𝑑
Circular Pitch (unit mm), 𝑝𝑐 = ,
𝑁
𝑑
Module (unit mm), 𝑚 = ,
𝑁
𝑁
Diametral Pitch (unit 1/inch), 𝑝𝑑 = → 𝑝𝑑 𝑝𝑐 = 𝜋
𝑑
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 19
Backlash
Backlash – the clearance between mating teeth measured at the
pitch circle.
Whenever torque changes sign, teeth will move from one side of
contact to another.
Can cause an error in position.
Backlash increases with increase in center distance.
Can have anti-backlash gears.
Anti-backlash gears
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 20
Interference and Undercutting
Interference – If there are too few pinion teeth, then the gear
cannot turn
Undercutting – part of the pinion tooth is removed in the
manufacturing process
For no undercutting
f (deg) Min # teeth
14.5 32
20 18
25 12
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 21
Simple Gear Trains
Maximum gear ratio of 1:10 based on size
constraints
Gear ratios cancel each other out
Useful for changing direction
𝑁2 𝑁3 𝑁4 𝑁5
𝜔𝑜𝑢𝑡 = − − − − 𝜔𝑖𝑛
𝑁3 𝑁4 𝑁5 𝑁6
𝑁2
𝜔𝑜𝑢𝑡 = 𝜔𝑖𝑛
𝑁6
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 22
Compound Gear Trains
More than 1 gear on a shaft
Allows for larger gear train ratios,
𝑁2 𝑁4 𝑁2 𝑁4
𝜔𝑜𝑢𝑡 = − − 𝜔𝑖𝑛 = 𝜔𝑖𝑛
𝑁3 𝑁5 𝑁3 𝑁5
Non-reverted
compound gair train
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 23
Compound Gear Trains
𝑁2 𝑁4
ω𝑖𝑛 = ω𝑜𝑢𝑡
𝑁3 𝑁5
For Reverted (inline) Gearbox
2
𝑁2
ω𝑖𝑛 = ω𝑜𝑢𝑡
If N2=N4 and N3=N5 𝑁3
2
ω𝑖𝑛 𝑁3
=
ω𝑜𝑢𝑡 𝑁2 Reduction ratio
reverted compound gair train
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 24
Compound Train Design: Exact RR
Factor desired ratio: 180 = 22 × 32 × 5
It is better to keep each ratio about the same (i.e. 6 × 6 × 5)
14 × 6 = 84
14 × 5 = 70
Total ratio
2
70 84
= 180
14 14
We could have used:
180=2x90=2x2x45=2x2x5x9=4x5x9 or 4.5x6x(20/3) etc.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 25
Manual Transmission
Low gear High gear
Reverse gear
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Manual Synchromesh Transmission
Based on reverted compound gears
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Reverted Compound Train
Input and output shafts
are aligned
For reverted gear trains:
R2+R3=R4+R5
D2+D3=D4+D5
N2+N3=N4+N5
Commercial three stage
Gear ratio is reverted compound train
ω𝑜𝑢𝑡 𝑁2 𝑁4
=
ω𝑖𝑛 𝑁3 𝑁5
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 29
Design a reverted compound gear train
◦ 18 = 3 × 6 𝑁3 = 6𝑁2 , 𝑁5 = 3𝑁4 𝑁3 𝑁5
= 18
𝑁2 𝑁4
◦ 𝑁2 + 𝑁3 = 𝑁4 + 𝑁5 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡
◦ 𝑁2 + 6𝑁2 = 𝑁4 + 3𝑁4 = 𝐶
◦ 7𝑁2 = 4𝑁4 = 𝐶 𝑁3 𝑁5
=6 =3
Take 𝐶 = 28 then 𝑁2 = 4, 𝑁4 = 7 𝑁2 𝑁4
This is too small for a gear!
Choose 𝐶 = 28 × 4 = 112 (𝑠𝑎𝑦)
𝑁4 = 28, 𝑁5 =84
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 30
Planetary or Epicyclic Gears
Conventional gearset has one DOF
If you remove the ground at gear 3, it has two DOF
It is quite difficult to access 𝜔3
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Planetary or Epicyclic Gears
Planetary Gearset with Planetary Gearset with
Fixed Ring Fixed Arm
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Planetary Gearset with Ring Gear Output
Two inputs (sun and arm) and one output (ring) all on concentric
shafts
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 33
Different Epicyclic Configurations
Gear plots are about axis of rotation/symmetry
bearing
Ring (internal)
teeth
Axis of
symmetry
Sun (external)
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 34
Different Epicyclic Configurations
Gear plots are about axis of rotation/symmetry
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 35
Compound Epicycloidal Gear Train
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Tabular Method For Velocity Analysis
Basic equation: wgear=warm+wgear/arm
Gear ratios apply to the relative angular velocities
Gear# wgear= warm wgear/arm Gear
ratio
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Example 1
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Tabular Method For Velocity Analysis
N2=40, N3=20, N4=80 Sign convention:
Clockwise is negative (-)
warm= -200 rpm (clockwise) Anti-clockwise is positive(+)
wsun= -100 rpm (clockwise)
Gear# wgear= warm+ wgear/arm Gear
ratio
2 -100 -200 100 40
−
20
3 - 400 -200 -200 20
+
80
4 -250 -200 -50
w4= - 250 rpm
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 39
Example 2
For the planetary gear train shown,
the carrier (link 2) serves as the
input to the train. The ring gear
(gear 1) is the fixed gear and has
100 teeth. The planet gear (gear 4)
has 40 teeth.
The sun gear (gear 3) serves as the
output from the train.
Determine the rotational velocity
of all members of this gear train
when the input shaft rotates at
1200 rpm clockwise.
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 40
Example 2
𝑁1 = 100, 𝑁3 =?, 𝑁4 = 40
𝜔𝑎𝑟𝑚 = −1200
Calculate the output velocity of Gear 5.
Gear# wgear= warm+ wgear/arm Gear
𝑁1 = 100 ratio
0 -1200 1200 100
𝑁4 = 40 1
40
1800 -1200 3000
4 40
−
20
3 -7200 -1200 -6000
𝑁3 = 20
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 41
Example 3
Repeat example 2, for the following data
𝑁1 = 100, 𝑁3 =?, 𝑁4 = 40
𝜔𝑎𝑟𝑚 =? , 𝜔3 = −7200
Calculate the output velocity of the arm.
𝑁1 = 100
𝑁4 = 40 Gear# wgear= warm+ wgear/arm Gear
ratio
0 0.2x -0.2x 100
1
40
1800 0.2x -0.5x
𝑁3 = 20
4 40
−
20
-7200 0.2x x
-7200 = 1.2x 3
∴ x = −6000
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 42
Example 4
𝑁2 = 40, 𝑁3 = 20, 𝑁4 = 30, 𝑁5 =?
𝜔𝑎𝑟𝑚 = −100, 𝜔𝑠𝑢𝑛 = 200
Calculate the output velocity of Gear 5.
Gear# wgear= wwarm
arm+ wgear/arm Gear
#2 200 -100 300 ratio
-40
#3 -700 -100 -600 20
1
#4 -700 -100 -600
30
90
#5 -300 -100 -200
Nile University MENG 306 Kinematics and Dynamics of Mechanical Systems Dr. Ahmed Asker 43
