BITS Pilani

Pilani Campus

VINAYAK KALLURI

BITS Pilani
Pilani Campus

Introduction
Mechanical Drive : a mechanism which is intended to transmit mechanical power over a certain distance, usually in terms of speed and torque Mechanical Drives are classified into two groups according to their principle of operation Mechanical drives that transmit power by means of engagement , e.g., gear drives and chain drives. Mechanical drives that transmit power by means of friction , e.g., belt drives and rope drives. The selection of proper mechanical drive for a given application depends upon number of factors like centre distance, velocity ratio, shifting arrangement, maintenance considerations and cost.
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Gear Drives Toothed wheels, which transmit power and motion from one shaft to another by means of successive engagement of teeth. Most suitable drive, if the centre distance is small The efficiency of gear drives is very high compared to other mechanical drives ( up to 99 %) Changing a velocity ratio over a wide range is possible, with the help of special provision called gear box.
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Gear Drives In any pair of gears, the smaller one is called pinion and the larger one is called gear immaterial of which is driving the other When pinion is the driver, it results in step down drive in which the output speed decreases and the torque increases when the gear is the driver, it results in step up drive in which the output speed increases and the torque decreases.
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Classification Gears are arranged between two shafts , which are 1. Parallel 2.Intersecting 3.Non parallel & Non intersecting

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Spur Gear Used to transmit motion between two parallel shafts Teeth parallel to the axis of rotation It has the largest applications and easy to manufacture

Spur Gear

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Helical Gear
Also used for parallel shafts, like spur gears Teeth inclined to the axis of rotation. The inclined tooth develops thrust loads Quiet in operation Teeth engage gradually reducing shocks

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Herringbone Gears
Two helical gears with opposing helical angles side-by-side Axial thrust gets cancelled

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Bevel Gear
Teeth formed on conical surfaces and straight teeth tapering towards an apex Used for transmitting motion between intersecting shafts Simple and most commonly used gear in bevel gear family

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Bevel Gear Spiral Bevel Gear

A bevel gear with a helical angle of spiral teeth. More complex to manufacture, but offers a higher strength and lower noise

Zerol Bevel Gear

A spiral bevel with zero degree of spiral angle tooth advance It has the characteristics of both the straight and spiral bevel gears

Miter Gear
For one to one ratio Used to change the direction
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Hypoid Gear
Similar to spiral bevel gears, but have non intersecting axis Blanks of hypoid gears are hyperboloids of revolution. Hence the name.

Crossed Helical Gear

Two helical gears of opposite helix angle will mesh if their axes are crossed Strength is very less due to point contact Also called as screw gears
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Worms and worm gears

oUsed for large speed reductions (more than 3) between two perpendicular and non-intersecting shafts o Driver called worm resembles a screw.

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Classification Summary
GEARS

Parallel shaft

Intersecting Shaft

Non Parallel & Non Intersecting Shaft

Spur

Helical

Bevel

Single

Double (Herringbone)

Crossed helical

Hypoid

Worm

Bevel

Zerol Bevel

Spiral Bevel

Miter
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Classification: A special cases

Rack and pinion Comprises a pair of gears which convert rotational motion into linear motion. circular pinion engages teeth on a linear "gear( the rack) Rotational motion applied to the pinion will cause the rack to move to the side, up to the limit of its travel.

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Classification: A special cases

INTERNAL GEAR Used to transmitting motion between two parallel shafts Annular wheels are having teeth on the inner periphery The meshing pinion and annular gear are running in the same direction

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For Different GEARS

Gear Geometry Nomenclature Gear Force Analysis Gear tooth Bending strength Gear tooth Surface fatigue Design of Gear Drive

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NOMENCLATURE

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IMPORTANT PARAMETERS OF GEARS

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Conjugate Action
Cam A and follower B in contact. When the contacting surfaces are involutes profiles, the ensuing conjugate action produces a constant angularvelocity ratio.

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Law of Gearing

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Law of Gearing
V1cos = V2cos

Because of similar triangles

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Law of Gearing
When two gears are in mesh, their pitch circles roll on one another without slipping.

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Constructing an involute profile

Divide the base circle into a number of equal parts, and construct radial lines OA0, OA1, OA2, etc. Beginning at A1, construct perpendiculars A1B1, A2B2, A3B3, etc.

A0-starting point A1B1=A1A0 A2B2=A2A0 and so on

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Involute curve

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Involute curve

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Gear involute action

To transmit motion at a constant angular-velocity ratio, the pitch point must remain fixed; that is, all the lines of action for every instantaneous point of contact must pass through the same point P.
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Gear layout circles

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Pressure line or line of action and pressure angle

the radius of the base circle, rb = r cos

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A template for drawing gear teeth.

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Tooth action in involute profiles

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Line of action

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Tooth Systems

Standard and Commonly Used Tooth Systems for Spur Gears

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Tooth Systems

Tooth Sizes in General Uses

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Contact Ratio

Arc of action

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BITS Pilani, Pilani Campus

Problem:
A spur gear set has a module of 4 mm and a velocity ratio of 2.8. the pinion has 20 teeth. Find the number of teeth on the driven gear, the pitch diameters, and theoretical center-to-center distance. If a contact length is 20 mm and pressure angle is 250, then find the contact ratio.

Ans:

P= m = 12.56 mm mc = Lab/ p cos = 20/ 12.56 x cos 250 = 1.75

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Interference in gears, why it occurs?

1) Due to the presence of noninvolute portion on the tooth below the base circle 2) Interference is present if C & D, the points of tangency of line of action to the base circles, lie inside the initial and final points of contact (equal to the points of intersection of the line of action with the addendum circles).
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Interference in gears
The consequence of interference is cutting away of material resulting in weakening of the gears against fatigue. When gear teeth are produced by a generation process, interference is automatically eliminated because the cutting tool removes the interfering portion of the flank. This effect is called as undercutting. But gear generation is not a solution to interference problem because the gear would anyway have been weakened in strength. The solution lies in controlling the minimum number of teeth on the pinion and the pressure angle. Rober Lipp (Machine Design, Vol. 54, 1982) carried out a detailed study on the control of the interference in gears.
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Avoiding Interference in Gears (Robert Liipp study)

For a 20 pressure angle, with k = 1, NP =13 i.e. 13 teeth on pinion and gear are interference-free.

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Interference in Gears
Interference can also be avoided (or reduced) by using a larger pressure angle. This results in a smaller base circle, so that more of the tooth profile becomes involute. Thus the demand for smaller pinions with fewer teeth will require the pressure angle of 25 degrees The pressure angle can not be arbitrarily large because a larger pressure results in higher bearing loads Lower the torque capacity and Decreased contact ratio
L1ab
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Problem: 138
For a spur gear-set with = 20, while avoiding interference, find: (a) The smallest pinion tooth count that will run with itself (b) The smallest pinion tooth count at a ratio mG = 2.5, and the largest gear tooth count possible with this pinion (c) The smallest pinion that will run with a rack

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BITS Pilani, Pilani Campus

Parallel Helical Gears

Parallel helical gears are used to transmit motion between parallel shafts. The helix angle is the same on each gear, but one gear must have a right-hand helix and the other a left-hand helix. The initial contact of spur-gear teeth is a line extending all the way across the face of the tooth. The initial contact of helical-gear teeth is a point that extends into a line as the teeth come into more engagement.
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Parallel Helical Gears

In spur gears the line of contact is parallel to the axis of rotation; in helical gears the line is diagonal across the face of the tooth. It is this gradual engagement of the teeth and the smooth transfer of load from one tooth to another that gives helical gears the ability to transmit heavy loads at high speeds. Helical gears subject the shaft bearings to both radial and thrust loads. To avoid thrust, a double helical gear (herringbone) is equivalent to two helical gears of opposite hand, mounted side by side on the same shaft. When two or more single helical gears are mounted on the same shaft, the hand of the gears should be selected so as to produce the minimum thrust load.
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Parallel Helical Gears

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Standard Tooth Proportions for Helical Gears

[1 mn] [1.25 mn]

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Problem A parallel helical gearset consists of a 19-tooth pinion driving a 57-tooth gear. The pinion has a left-hand helix angle of 30, a normal pressure angle of 20, and a normal module of 2.5 mm. Find: (a) The normal, transverse, and axial circular pitches (b) The transverse diametral pitch and the transverse pressure angle (c) The addendum, dedendum, and pitch diameter of each gear

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Solution

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Interference in helical gears

The smallest tooth number NP of a helical-spur pinion that will run without interference with a gear with the same number of teeth is Gear ratio mG = NG/NP = m, the smallest pinion tooth count is

Largest gear with a specified pinion is

The smallest pinion that run with a rack is

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Problem: 139
For a helical gear-set with = 20 and = 30 while avoiding interference, find: (a) The smallest pinion tooth count that will run with itself (b) The smallest pinion tooth count at a ratio mG = 2.5, and the largest gear tooth count possible with this pinion (c) The smallest pinion that will run with a rack

BITS Pilani, Pilani Campus

BITS Pilani, Pilani Campus