Chapter 2

design of gears

Dr.Johnson
JIMMA UNIVERSITY
JIMMA INSTITUTE OF TECHNOLOGY
SCHOOL of MECHANICAL ENGINERING

MACHINE ELEMENT II
 Introduction
Power transmission devices are very commonly used
to transmit power from one shaft to another.
Gears, Belts, and Chains are used for this purpose.
Gear drive is used for short distances.
When the distance between the shafts is large,
belts or ropes are used and
For intermediate distance chains can be used.
For belt drive distance can be maximum but this
should not be more than ten meters for good
results.
 Gear drive

Gear are also used for power transmission.

It is accomplished by the successive engagement
of teeth. Two gears transmit motion by the direct
contact of teethes.
It is a positive drive.
 Gear drive
• Why use Gears:
.
 Gears range in size from miniature instrument installations,
such as watches, to large, powerful gears used in turbine
drives for ocean liners.
 Gears offer positive transmission of power.
 Transmission ratio can be freely controlled with high accuracy
by changing the number of gear teeth.
 Gears can couple power and motion between shafts whose
axis are parallel, intersecting or skew.
 Advantages and Disadvantages of
Gear Drives

Advantages
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small centre distances
of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Disadvantages
1. Since the manufacture of gears require
special tools and equipment, therefore it is
costlier than other drives.
2. The error in cutting teeth may cause
• In bicycle gears are used to
vibrations and noise during operation.
3. It requires suitable lubricant and reliable transmit motion.
method of applying it, for the proper • Mechanical advantage can be
operation of gear drives. changed by changing gears.
 GEARS
• Transmit motion between shafts
• Gear types
– Spur gears – parallel shafts – most common
– Bevel gears – perpendicular shafts
– Worm gears - perpendicular overlapping shafts
– Rack and pinion gears – convert circular motion to
linear motion
Categories of Gears Types of Gears

Spur gear

Parallel Axes
Gears Helical gear

Spur (helical) rack

Straight bevel gear

Intersecting Axes
Spiral bevel gear
Gears

Helical gear

Nonparallel and
Nonintersecting Worm gears
 GEARS

SPUR
GEAR

WORM
GEAR BEVEL
GEAR
Spur Gear Design

Pinion

Gear
 Spur Gears
• Teeth are parallel to the
axis of the gear
• Advantages
– Cost
– Ease of manufacture
– Availability
• Disadvantages
– Only works with mating
gear
– Axis of each gear must be
parallel
•
Helical
Teeth are at an angle to the gear axis
Gears
(usually 10° to 45°) – called helix angle
• Advantages
– Smooth and quiet due to gradual
tooth engagements (spur gears
whine at high speed due to
impact). Helical gears good up to
speeds in excess of 5,000 ft/min
– More tooth engagement allows for
greater power transmission for
given gear size.
• Disadvantage
– More expensive
– Resulting axial thrust component
 Helical Gears
• Mating gear axis can be
parallel or crossed
• Can withstand the
largest capacity at
30,000 hp
 Worm Gears worm gear

• Gears that are 90° to each

other
• Advantages
– Quiet / smooth drive
– Can transmit torque at right
angles
– No back driving
– Good for positioning systems
• Disadvantage
– Most inefficient due to
excessive friction (sliding)
– Needs maintenance worm
– Slower speed applications
 Bevel Gears
• Gear axis at 90°, based on
rolling cones
• Advantages
– Right angle drives
• Disadvantages
– Get axial loading which
complicates bearings and
housings
 Spiral Bevel Gears

• Same advantage over

bevel gears as helical
gears have over spur
gears!!
• Teeth at helix angle
• Very Strong
• Used in rear end
applications (see
differentials)
 Why Use Gears?
1. Reduce speed
2. Increase torque
3. Move power from one point to another
4. Change direction of power
5. Split power

Generally this functionality is accomplished by many gears mounted in a gear

box!
 Boston
Gear

Examples
of “off the
shelf”
drives

Show slides
John Deere 3350 tractor cut in Technikmuseum Speyer Museum
 Gears vs Belts and Chains
• Gears are much more capable in terms of power
rating (helical gear drives capable of > 30,000 hp)
• With planetary gear sets large gear ratio’s can be
achieved (100:1)
• Gear applications include high torque and high
speeds
• Can have multiple speed reductions by pairing
different gears or gear trains (several gears in
series)
 Gears used for Speed Reducer
• Recall the main purpose of mating/meshing gears is to
provide speed reduction or torque increase.

Pitch line speed  vt  R  (D / 2)

nP N G N driven
Velocity Ratio  VR   
nG N P N driver

Gear
Pinion Speed-nG
Speed-nP
No of Tooth- NG
No of Tooth- NP

vt ( ft / min)  (Dn / 12)

DRIVER GEAR AND DRIVEN GEAR
 Example:

Want a 3:1 reduction

• NP=22 teeth
• What is NG?
• Solution:
– VR = 3 = NG/NP

– NG = 3*22 = 66 teeth
Conclusion:
•Total speed reduction =
1750/68 = 25.7
•Torque increase = 25.7
•Power = constant!!
 n4, N4
n1, N1
Engine
Pump
Given: n2, N2

n1 = 500 rpm, N1 = 20t

N2 = 70t, N3 = 18t, N4 = 54t n3, N3

Find: n4

Example: Double Speed Reducer

Solution:
1. n2 = 500 rpm*(20/70) = 142.8 rpm Torque?? Increases by 10.5!!
Power?? Stays the same
2. n3 = n2 throughout!
3. n4 = 142.8 rpm*(18/54) = 47.6 rpm
4. Total reduction = 500/47.6 = 10.5 (0r
10.5:1)
 Basic Law of Gearing:
–A common normal (the line of action) to the tooth profiles
at their point of contact must, in all positions of the
contacting teeth, pass through a fixed point on the line-
of-centers called the pitch point
–Any two curves or profiles engaging each other and
satisfying the law of gearing are conjugate curves, and
the relative rotation speed of the gears will be constant
 Pinion
Line drawn perpendicular at
point of contact always crosses
centerline at same place then POWER
VR = np/nG = constant np

Law of Kinematics

Holds true if teeth have

conjugate profile!!
 Spur Gear Nomenclature
• Pitch Circle(s)
– The circles remain tangent
throughout entire
engagement
• Pitch Diameter
– Diameter of pitch circle
DP – Pitch f of pinion
DG – Pitch f of gear
(power gear or driving gear)
(Driven gear)
 Gear Nomenclature
• N = Number of teeth
– Use subscript for specific gear
• NP=Number of teeth on pinion (driver)
• NG=Number of teeth on gear (driven)
• NP < NG (for speed reducer)
• NA=Number of teeth on gear A
• Circular Pitch, P is the radial distance from a
point on a tooth at the pitch circle to
corresponding point on the next adjacent
tooth P=(p*D)/N
 Gear Nomenclature
• Gear Train Rule – Pitch of two gears in mesh
must be identical

PINION
pDG pDP
P=
NG NP

GEAR
 Gear Nomenclature
• Diametral Pitch, (Pd) – Number of teeth per mm of pitch
diameter

N
Pd =
D
*Two gears in mesh must have equal Pd:
NG NP
Pd = =
DG DP
*Standard diametral pitches can be found in Table 8-1 and 8-2
 DIAMETRAL PITCH
NUMBER OF TEETH PER cm OF PITCH DIAMETER

18 TEETH
EXAMPLE:
Gear has 18 teeth and a pitch
diameter of 9cm

=
18 TEETH ? TEETH
9c
m P= 9cm = 1 mm

Diametral Pitch (tooth size) = 18

teeth/9cm = 2cm

P = 2cm
 GEAR RATIO
Ratio of number of teeth on one gear to
number of teeth on the mating gear

Ratio = 9/18, or 1/2 Ratio = 25/18

GEAR TERMINOLOGY

OUTSIDE DIAMETER
PITCH DIAMETER

ROOT DIAMETER

DIAMETRAL PITCH
= TOOTH SIZE

CENTER
DISTANCE
 MATING SPUR GEARS
TANGENT PITCH CIRCLES D2

D1

D1 + D2 COMPARE TOOTH SIZES

= CC DIST
2

ER
O- C EN T
TE R-T CE
CEN DISTAN
PRESSURE ANGLE Force perpendicular
at f

Φ = 14.5˚ Φ = 20˚ Φ = 25˚

 Gear Nomenclature Example
8-1) Gear has 44 teeth, Æ=20°, full depth
involute form diametral pitch Pd = 12
– Pitch Diameter
NG 44 teeth
DG = = 12 t/cm = 3.667 cm
Pd
– Circular Pitch
p DG (p) 3.667cm
Pc = = = .2617 cm/t
NG 44 t
 Gear Nomenclature Example
• Addendum
1 1
a = = = .0833 cm
Pd 12 t/cm
Dedendum
1.25 1.25
b= = = .1042 cm
Pd 12 t/cm
 Gear Nomenclature Example
• Clearance

.25 .25
c = = = .0208 cm
Pd 12 t/cm
• Whole Depth
ht = a+b = .1875 cm

• Working Depth
hk = 2*a = .16667 cm
 Gear Nomenclature Notes
• Clearance maybe a problem for small pinions driving
large gears, therefore they won’t mesh and will lock up

• As NP decreases so does max NG

• If design necessitates small pinion, maybe able to

increase clearance by undercutting gear tooth (See
Figure 8-14)
Summary of Gear Nomenclature:

D = Pitch diameter of pinion

P

D = Pitch diameter of gear

G

N = No. teeth (t) for pinion

P

N = No. teeth (t) or gear

G

P = diametral pitch = N/D = constant for meshing gears

d
p = circular pitch = pD/N = constant for meshing gears
n = speed of pinion (rpm)
P

n = speed of gear (rpm)

G

VR = velocity ratio = nP/nG = NG/NP

Power = constant across mating gears or series system:
 Pin = Pout

Power in branched system is conserved:

 Pin = P + P + …..
A B
Torque will change!! P= 2pNT/60
 Module, m = D / T

It is the ratio of the pitch circle diameter in

millimetres to the number of teeth. It is
usually denoted by m
The recommended series of modules in Indian Standard are 1,
1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16,
20, 25, 32, 40 and 50.
The modules 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5,5.5, 7, 9, 11,
14, 18, 22, 28, 36 and 45 are of second choice.
Standard Proportions of Gear Systems
Problem:1
A gear drive is required to transmit a maximum power of
22.5 kW. The velocity ratio is 1:2 and r.p.m. of the pinion
is 200. The approximate centre distance between the
shafts may be taken as 600 mm. The teeth has 20° stub
involute profiles. The static stress for the gear material
(which is cast iron) may be taken as 60 MPa and face
width as 10 times the module. Find the module, face
width and number of teeth on each gear. Check the
design for dynamic and wear loads. The deformation or
dynamic factor in the Buckingham equation may be taken
as 80 and the material combination factor for the wear as
1.4.
Problem:2
A pair of straight teeth spur gears, having 20° involute
full depth teeth is to transmit 12 kW at 300 r.p.m. of
the pinion. The speed ratio is 3 : 1. The allowable static
stresses for gear of cast iron and pinion of steel are 60
MPa and 105 MPa respectively. Assume the following:
Number of teeth of pinion = 16; Face width = 14 times
module; Velocity factor (Cv ) =
v being the pitch line velocity in m / s; and tooth form
factor (y) =
Determine the module, face width and pitch diameter
of gears. Check the gears for wear; given σes = 600
MPa; EP = 200 kN/mm^2 and EG = 100 kN/mm^2.
Sketch the gears.
THANK YOU