Gears

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MECE 304 Mechanical Machine Elements-Gears

LECTURE NOTES- MECE 304 Mechanical Machine Elements Chapter 8- Gears (Notes from: Chapter 13, Budynas R.G., Nisbett J.K., Shigleys Mechanical Engineering Design, Mc Graw Hill, 8th Edition and special notes)

MECE 304 Mechanical Machine Elements-Gears

13-1 Types of gears 1-Spur gears 2- Helical gears 3-Bevel gears 4-Worm gears

MECE 304 Mechanical Machine Elements-Gears

Spur Gears

MECE 304 Mechanical Machine Elements-Gears

Helical Gears

MECE 304 Mechanical Machine Elements-Gears

Bevel Gears

MECE 304 Mechanical Machine Elements-Gears

Worm Gears

MECE 304 Mechanical Machine Elements-Gears

Fig 13-5 Nomenclature of a spur gear teeth

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MECE 304 Mechanical Machine Elements-Gears

13-2 Nomenclature The pitch circle is the theoretical circle upon which all calculations are based; its diameter is the pitch diameter The circular pitch p is the distance from a point on one tooth to a corresponding point on an adjacent tooth. The module m is the ratio of the pitch diameter to the number of teeth. It is the index of tooth size in SI. The diametral pitch P is the ratio of the number of teeth to the pitch diameter. P is used with U.S. units. Addendum is the radial distance between top land and pitch circle Dedendum is the radial distance between pitch circle and bottom land. P=N/d m=d/N p= d/N= m pP= 13-1 13-2 13-3 13-4
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MECE 304 Mechanical Machine Elements-Gears

where P=diametral pitch N=number of teeth d= pitch diameter, in m=module, mm d=pitch diameter, mm p=circular pitch The relation between P and m are as follows Diametral pitch=25.4 / Module

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MECE 304 Mechanical Machine Elements-Gears

Metric Gears Geometrical Relations (without profile modification) (yellow color are controlling parameters of the gears)
Parameter Description Formula Type or unit

m Z p S ha

Pressure angle Module Number of teeth Pitch of the teeth,on a straight generative rack. Circular tooth thickness, measured on the pitch circle. Addendum = height of a tooth above the pitch circle. Dedendum = depth of a tooth below the pitch circle. (For m>1.25) Radius of the pitch circle. Radius of the outer circle. Radius of the root circle. Radius of the base circle. Radius of the root concave corner.

*m p/2 ha=m

degree millimeter integer millimeter millimeter millimeter

hf r ra rf rb rc

hf = m * 1.25 m*Z/2 r + ha r - hf r * cos( ) 0.38 * m

millimeter millimeter millimeter millimeter millimeter millimeter

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MECE 304 Mechanical Machine Elements-Gears

13-3 Congugate action When the tooth profiles are designed so as to produce constant angular velocity ratio during meshing these are said to have congugate action

Fig 13-6 When contacting surfaces of cam A and follower B are involute profiles, congugate action produces constant angular velocity ratio

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MECE 304 Mechanical Machine Elements-Gears

13-4 Involute properties

Base circle:The circle on which the involute is generated

Fig 13-7 (a) generation of an involute, (b) involute action

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13-5 Fundamentals

Fig 13-8 Construction of a involute curve

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Fig 13-9 Circles of a gear layout

1/ 2=r2/r1

13-5
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MECE 304 Mechanical Machine Elements-Gears

Fig 13-9 Relation of base circle to pitch radius by pressure angle: rb=r cos

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Fig 13-12 Tooth action

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Fig 13-13 Rack and pinion

pb=pc cos where pb is base pitch and pc is circular pitch

13-7

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Fig 13-14 Internal gear and pinion

Addendum circle of internal gear lies inside the pitch circle.

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Compound gears: Compound gears are gears attached to each other and rotating around the same axis.

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MECE 304 Mechanical Machine Elements-Gears

Backlash: Is the amount by which the width of a tooth space exceeds the thickness of the engaging tooth measured on the pitch circles

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MECE 304 Mechanical Machine Elements-Gears

13-6 Contact ratio AP+PB=qt (arc of action) Contact ratio=mc=qt/p (gears to be designed with mc>1.2) mc indicates the number of gears in contact or mc=Lab/p*cos 13-8

Fig 13-15 Definition of contact ratio

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MECE 304 Mechanical Machine Elements-Gears

13-7 Interference The contact of tooth profiles that are not congugate are called interference **In gear interference, the involute tip of the driven gear tends to dig out the non-involute flank of the driver. **Interference can be eliminated by using more teeth on the gears or by using a larger pressure angle. The demand for smaller pinions with fewer teeth favors the use of a 25 pressure angle. **As a rule of thumb, use at least 14 teeth in a pinion.
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MECE 304 Mechanical Machine Elements-Gears

13-8 Forming of Gear Teeth Machining: Milling, Shaping, Hobbing Finishing: Shaving, Burnishing, Grinding, Lapping 13-9 Straigth Bevel Gears Transmits motion betweeen intersecting shafts

tan =NP/NG tan =NG/NP

Fig 13-20 Terminology of bevel gears

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MECE 304 Mechanical Machine Elements-Gears

13-10 Parallel Helical Gears Transmit motion between parallel shafts. Helix angle is the same for the 2 gear set but hands are different (rigth hand and left hand helix)

Fig 13-21 An involute helicoid

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MECE 304 Mechanical Machine Elements-Gears

Parallel Helical Gears pn=ptcos px=pt/tanc Pn=Pt/cos Cos=tann /tant where px=axial pitch pt= transverse circular pitch pn=normal circular pitch Pn=normal diametral pitch Pt=transversal diametral pitch = helix angle Fig 13-22 Nomenclature of helical gears
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MECE 304 Mechanical Machine Elements-Gears

13-12 tooth systems Is a standard that specifies the relationship involving addendum, dedendum, working depth, tooth thickness and pressure angle Table 13-1 Standard and Commonly Used Tooth Systems for Spur Gears
Tooth System Full depth Pressure Angle deg. 20 221/2 25 Stub 20 Addendum a 1/Pd or m 1/Pd or m 1/Pd or m 0.8/Pd or 0.8m Dedendum b 1.25/Pd or 1.25m 1.35/Pd or 1.35m 1.25/Pd or 1.25m 1.35/Pd or 1.35m 1.25/Pd or 1.25m 1.35/Pd or 1.35m 1/Pd or m

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MECE 304 Mechanical Machine Elements-Gears

13-12 tooth systems Table 13-2 Tooth sizes in general uses

Diametral Pitch Coarse 2, 21/2, 21/2, 3, 4, 6, 8, 10, 12, 16 Fine 20, 24, 32, 40, 48, 64, 80, 96, 120, 150, 200 Modules Preferred 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12, 16, 20, 25, 32, 40, 50 Next Choice 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14, 18, 22, 28, 36, 45

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MECE 304 Mechanical Machine Elements-Gears

13-12 tooth systems Table 13-4 Standard Tooth Proportions for Straigth Helical Gears
Quantity Addendum (a) Dedendum (b) Pinion pitch diameter Gear pitch diameter Normal arc tooth thickness Pinion base diameter Gear base diameter Base helix angle Formula 1.00 [mn ] Pn 1.25 [1.25mn ] Pn
N p mn Pn cos cos N G N G mn Pn cos cos Np

Quantity External gears: Standard center dis. Gear outside diameter Pinion outside diameter Gear root diameter Pinion root diameter Internal gears: Center distance Inside diameter Center distance

Formula

D+d 2 D+2a

d+2a D-2b d-2b

Dd 2 D-2a D+2b
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Pn

Bn 2

B m n n 2

d cost D cost tan-1[tan cost

MECE 304 Mechanical Machine Elements-Gears

13-13 Gear trains If a pinion 2 is driving a gear 3 than n3=(N2/N3)n2=(d2/d3)n2 where n=rpm N=number of teeth d=pitch diameter

13-29

Fig 13-27 A gear train

.
e= product.of .driving.tooth.numbers product.of .driven.tooth.numbers
13-30
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MECE 304 Mechanical Machine Elements-Gears

nL=e*nF nL=speed of last gear, nF=speed of first gear

13-31

Notes: **Gear ratio between two gears should not exceed 6 (may be up to 10 in certain cases). This should also be extended to train values of gear trains such that: e 35 for a 3-gear system e 150 for a 4-gear system ** Gear ratio should not be an integer number. Otherwise the same set of teeth will come in contact repeatedly, thus generating an unwanted wear

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MECE 304 Mechanical Machine Elements-Gears

Planetary Gear trains: Gear trains in which some of gear axis rotate about axis of the other gears

Fig 13-31 A gear train on the arm of a planetary gear train Fig 13-30 A planetary gear train
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MECE 304 Mechanical Machine Elements-Gears

Planetary Gear trains: From figure 13-31 n23=n2-n3 and n53=n5-n3 If we divide the 2 equations side by side

n53 n5 n3 = n 23 n 2 n3 e= n L n3 n F n3
13-32

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MECE 304 Mechanical Machine Elements-Gears

13-14 Force analysis-Spur Gears Power (H) transmitted is : H=T* To convert to customary units: V= d*n (V= d*n/12) Where V= pitch line velocity mm/sec (ft/min) d=gear diameter mm (inch) n=gear speed rev per sec (rpm) Wt=(60000H)/ d*n (Wt=33000*H/V) where Wt=transmitted load kN (lbf) H=power kw (hp) d=gear diameter, mm n=speed rpm (V=pitch line velocity, ft/min)

13-33

13-34

13-36

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MECE 304 Mechanical Machine Elements-Gears

Force analysis-Spur Gears

Fig 13-32 Spur gears free body diagrams

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13-15 Force analysis Straigth Bevel gears Wt=T/rav 13-37 where T is the torque, rav is the pitch radius at the midpoint of tooth for the gear under consideration Wr=Wt*tan *cos Wa=Wt*tan *sin 13-38

Fig 13-35 Bevel gear tooth forces (see also Fig 13-20)
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MECE 304 Mechanical Machine Elements-Gears

13-16 Force analysis Helical Gearing

Wr = W sinn Wt = W cosn cos Wa = W cosn sin where W= total force Wr=radial component Wt=tangential component (transmitted load) Wa = axial component (thrust load)

Fig 13-37 Tooth forces acting on a rigth hand helical gear

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MECE 304 Mechanical Machine Elements-Gears

Notes **Helical gears subject the shaft bearings both radial and axial loads (see following figures for the direction of axial loads) **The initial contact of helical gear teeth is a point which extends into a line as the teeth come into more engagement. It is this gradual engagement of teeth and the smooth transfer of load from one tooth to another which give helical gears the ability to transmit heavy loads at high speeds. **When the thrust load is objectionable, it may be desirable to use double helical gears (herringbone)

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MECE 304 Mechanical Machine Elements-Gears

Direction of Axial Force in Helical Gear Systems

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