Mahesh A Kori

Gearing is a very vital form of transmission of mechanical power. Power transmission is the movement of energy from its place of generation to a location where it is applied to performing useful work A gear is a component within a transmission device that transmits rotational force to another gear or device
Universally adopted for almost all machine mechanisms.

TYPES OF GEAR TRANSMISSIONS: Spur Gear Helical Gear Herring bone Gear Bevel Gear Rack and pinion Worm and worm wheel

Functions of Gears
Change the speed of rotation Change the direction of rotation Increase or reduce the magnitude of speed and torque. Convert rotational movement into linear or vice versa (rack and pinion drive) Change angular orientation (bevel gears). Off set in the location of rotating movement (helical gears, and worm gear sets).

GEAR MANUFACTURING METHODS Casting Pouring Injection Molding Powder metallurgy

Rotary Disc Wheel Milling (Disc Cutter) Form Grinding (Disc wheel) Thread Grinding Rotary Threaded Wheel Hobbing Generation Grinding (Worm Type Grinding)

Forming Cold Drawing Gear Rolling -> Forging

Metal Removal Process

Linear Motion Tool Broaching Punching Shear Cutting Reciprocating Tools Shaping (Pinion Type) Shaving (Rotary Type)

Gear Cutting & Finishing

TYPES OF GEARS
According to the position of axes of the shafts. a. Parallel Spur Gear Helical Gear Rack and Pinion b. Intersecting Bevel Gear c. Non-intersecting and Non-parallel worm and worm gears

MACHINING Reproducing method, in which the cutting tool is a formed involve cutter, which forms the gear teeth profiles by reproducing the shape of the cutter itself. In this method, each tooth space is cut independently of the other tooth spaces. Form Cutting Milling machine Broaching machine Shaping machine Generating method in which the cutting tool (hob) forms the profiles of several teeth simultaneously during constant relative motion of the tool and blank.

Generating processes Gear hobbing Gear shaping Rack planning

SPUR GEAR
Spur (straight cut) gears are widely used in parallel shaft applications, such as transmissions, due to their low cost and high efficiency. The design allows for the entire gear tooth to make contact with the tooth face at the same instant. As a result, this type of gearing tends to be subjected to high shock loading and uneven motion. Design limitations include excessive noise and a significant amount of backlash during high-speed operation.

APPLICATIONS

Spur gears are made in a great variety of sizes from less; than 25 mm to several cm in diameter. Spur gears are made with both 14.1 and 20 pressure angles. Spur gears are made of steel, bras, other metals and plastics.

Product

Motorcycle Gear Box Sets Application 600cc, 800cc, 900cc, 1200cc Motorcycles Product Pump shafts Application Small oil pump for generators

Product Pump Gears Application Oil pump for earth moving equipments

HELICAL GEAR
Helical Gears can be used for transmitting motion between parallel shafts. Helical gears used for transmission at an angle are called SPIRAL GEARS.
Advantages of Helical Gears: Noiseless motion even at higher speeds. Smooth transmission of small gears with fewer teeth, at large transmission ratio ( up to 15:1) These gears must be rigidly installed on the shaft. These gears result in an axial force in one direction depending upon the direction of rotation and are used for transmitting small power.

Product

Forklift Gear Box Sets Application Forklift

Product Differential Application Ford, GM, F350, F450, 7000cc, 7500cc, 8000cc, and 8500cc heavy duty trucks

Helical gears operate more quietly and smoothly than spur gears. This is due to the fact that teeth of helical gears slide one across the other rather than hitting each other as in spur gears.
Moreover, unlike spur gears, in helical gears several teeth of each gear are in contact at one time and thus the load is spread, resulting in greater strength than if only one tooth of each gear is in contact at a time as in spur gears, However, in helical gears, the friction, heat generated and wear is high because of the sliding action of one tooth on another Therefore helical gears should run in oil bath as in automobile transmission. Another disadvantage with helical gearing is that helical gears exert an end thrust which must be absorbed by a thrust bearing.

HERRING-BONE GEAR
HERRING-BONE Gears are pairs of Helical Gears. These gears are used for large power transmission.

Advantages of Herring-bone Gears in addition to Helical Gears: No Axial Force. It is balanced axially in both direction of rotation. Large power transmission can be done at impact loads having frequent starts (inching). These gears also must be rigidly installed on the shaft.

Herringbone gears are an improvement over the double helical gear design. Both right and left hand cuts are used on the same gear blank, which cancels out any thrust forces. Herringbone gears are capable of transmitting large amounts of horsepower and are frequently used in power transmission systems.
The differences in gear design create the need for significantly different lubrication designs. For instance, gears normally seen in automotive differentials are hypoid gears and require GL-5 concentration and

Bevel Gear transmission is employed for transmitting motion from one direction to the other at any angle. In general 90 transmission.

BEVEL GEAR

A set of two bevel gears is used to transmit power from one shaft to another shaft which is not parallel to the first one. A pair of gears 1 and 2 for shafts whose centre lines meet at right angles.

Bevel gears are available with straight, helical and spiral teeth. Where smooth running is required to avoid noise at high speeds, the straight bevel gears are inferior to the spiral bevel gears.

Bevel gears are more expensive to cut than spur gears. The most usual sizes of bevel gears are 30O mm diameter and under. Bevel gears are used 1:1 for angular drive.

WORM & WORM WHEEL GEAR

Worm and worm wheel gives a large single stage speed reduction in perpendicular direction. Such transmission gives lower efficiency of transmission due to increased frictional losses. For a noiseless motion, worm 1 is usually made of medium carbon / alloy steel and the worm wheel 2 of bronze (or in some cast iron).

used to connect shafts whose centre lines do not meet is the worm gear.

Worm gear sets employ a specially-machined worm that conforms to the arc of the driven gear. This type of design increases torque throughput, improves accuracy and extends operating life. Primarily used to transmit power through non-intersecting shafts, this style of gear is frequently found in gear reduction boxes as they offer quiet operation and high ratios (as high as 100:1). Downfalls with this type of gear set are its efficiency, high price per HP and low ratios (5:1 minimum). Worms and worm gears are used when a large speed reduction ratio is wanted from one shaft to another.

Ratios as high as 70 to 1 can be made in with worm and worm gear, whereas the other types of gears cannot easily give more than about 6 to 1 in one pair. Nearly all worm gears work with shafts at 90, although they can be made for any shaft angle between about 80 and 100.

The teeth on the worm gear are helical and conform with the helix angle of the tooth on the worm. The helical tooth on the worm is a form of thread, similar to an acme thread. Worms may have single, double or triple threads. One revolution of a double thread worm revolves the worm gear aft amount equal to two teeth on the gear and so on.

RACK & PINION GEAR

The rotary motion of pinion 1 (small gear) is transformed into linear motion of the rack 2. For transmitting large power worm & worm rack transmission is employed.

steering system on cars

SPUR GEAR NUMENCLATURE

SPUR GEAR NUMENCLATURE

Nomenclature
Module Diametral Pitch Pitch Number of teeth Pitch Circle Diameter Tooth height Addendum Dedendum Root circle diameter Outside diameter Distance between the axis of the two mating gears t 1 & t2 Pressure angle

Symbol
m D.P. P t D h h h D1 Do

Formulae
m=p/ = D/t t/D = /p = 1/m P= .m = 3.14m t = D/m D = t.m h = 2.2 m h = m h = 1.2 m D1 = Do 4.4m Do = m (t+2)

A = (t1 + t2) m/2 20(usually) or 14

DEFECTS OF THE GEARS

Wear of one, few or all the teeth. One or few teeth broken or twisted. Burrs on the bore or the key way. Burrs on the internal splines of the gear bore or the tooth surface. Crack or damage on the rim or the bore of the gear wheel.

MESHING OF GEARS The spur and helical gears must be assembled in such a way that the axes of the meshing gears are parallel and the distance between their axes is correctly established. The correct meshing of the spur and helical gears is decided by applying blue paste on the teeth of the driving gear, giving it several rotations and seeing to the blue marks on the teeth faces of the meshing driven gear.

(a) Correct meshing covering 70 80% tooth surface contact. (b) Axis not parallel. (c) Axis not parallel and distance between them is too small. (d) Axis not parallel and distance between them is excess. (e) Axis are parallel and distance between them is excess. (f) Axis are parallel and distance between them is too small.

LUBRICATION
Proper Lubrication with timely addition / replacement plays vital role in maintaining the gear boxes with efficiency and increasing its working life. Oil level should be checked in all the gear boxes oil indicators / dip sticks. Oil level should be in between the minimum and maximum limits of the dip stick (or indicator). Testing of the lubricating oils used to be carried out periodically. The following tests are to be done 1. Dirt contamination 2. Moisture 3. Volatile materials (Benzene, kerosene, spirit etc,) 4. Viscosity 5. Acidity 6. Alkalinity due to soda (Na2 Co3) etc.,

BASE CIRCLE
Base circle : It is a circle from which involute form is generated. Only the base circle on a gear is fixed and unalterable. Base pitch (pb): It is the distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the base circle. Sometimes called the 'normal pitch'.

PITCH CIRCLE
Pitch is the distance between a point on one tooth and the corresponding point on an adjacent tooth. Pitch circle. A circle, centered on and perpendicular to the axis, and passing through the pitch point. Sometimes also called the 'pitch line', although it is a circle. Pitch diameter (D). Diameter of a pitch circle. The nominal gear size is usually the pitch diameter.

 Circular pitch (p). The distance from one face of a tooth to the corresponding face of an adjacent tooth on the same gear, measured along the pitch circle. Diametral pitch (Pd). The ratio of the number of teeth to the pitch diameter. Module (m). The module of a gear is equal to the pitch diameter divided by the number of teeth.

ADDENDUM AND DEDENDUM

Addendum : The radial distance from the pitch surface to the outermost point of the tooth. Dedendum : The radial distance from the depth of the tooth to the pitch surface.

POINT OF CONTACT
A point of contact is any point at which two tooth profiles touch each other. The pitch point is the point of tangency of two pitch circles and is on the line of centers.

LINE OF ACTION
The line of action is also called path of action.

It is the straight line passing through the pitch point and tangent to both base circles.

LANDS
Bottom land is the surface at the bottom of a gear tooth space adjoining the fillet.
Top land is the (sometimes flat) surface of the top of a gear tooth.

ANGLES ASSOCIATED WITH GEARS

Helix angle (). The angle between a tangent to the helix and the gear axis. It is zero in case of a spur gear.
Lead angle (). The angle between a tangent to the helix and a plane perpendicular to the axis. It is the complement of the helix angle which is usually given for helical gears.

Pressure angle (). The complement of the angle between the direction, that the teeth exert force on each other, and the line joining the centers of the two gears. The pressure angle is a constant for a given gear

Gear Milling

Advantages General purpose equipment and machines are used. Comparatively simple and easier setup is needed. Simple and cheap cutting tools are used. It is suitable for piece and small size production. Drawbacks Inaccurate process due to profile deviations and indexing errors. Low production capacity due to the idle time loss in indexing, approaching, and withdrawal of the tool. However, the productivity can be enhanced by multi-workpiece setup.

Gear Broaching
Progressive Broaching

Rotating Broach

Gear Shaping

Progressive Shaping Head

Gear Planing

Gear Hobbing

Gear Shaping with Pinion Cutter

Gear shaping with Rack Cutter

Gear Shaving

Gear Grinding

Gear Lapping