OMU-332

VEHICLE COMPONENT DESIGN

GEARS

Asst.Prof. zgr NVER

April 4th, 2016

Introduction

Why do we need gears/gearboxes?

To change;
rotational direction (cw to ccw)
rotational speed
torque
nput/output angle

Introduction
Spur Gear

Helical Bevel Gear

Helical Gear

Helical Hypoid Gear

Bevel Gear

Rack and Pinion

Spur Planetary Gear

Worm Gear

Interesting Links
Manufacturing
http://www.youtube.com/watch?v=yXAXvAXFwN0&feature=related
http://www.youtube.com/watch?v=L1x1TRO36gU&feature=related
http://www.youtube.com/watch?v=_j6KQ96YZM0&feature=related
https://www.youtube.com/watch?v=11UCwpKb5ME
https://www.youtube.com/watch?v=8pXtSWIJ7Ac
Explanation
http://www.youtube.com/watch?v=odpsm3ybPsA
http://www.youtube.com/watch?v=WYcqJ5HdxA4
http://www.youtube.com/watch?v=Hf9NoDT5nDk&feature=related
Mechanism
http://www.youtube.com/watch?v=de4xdOVVROQ&feature=relmfu
Stresses
https://www.youtube.com/watch?v=CtNF1fj0SCQ
https://www.youtube.com/watch?v=3HIJ0nvYF44

Gear History
Primitive gears were first used in door drive mechanism in

temples and caves, and water lifting mechanisms 2600 B.C.

Gears are toothed members which transmit power / motion

between two shafts by meshing without any slip.

Reference from this slide: Prof. K.Gopinath & Prof. M.M.Mayuram

Classification of Gears

Spur Gears
Teeth parallel to the axis,
Used for transmitting power between two parallel

shafts,
Simple in construction,
Easy to manufacture and cost less,
Highest efficiency
Excellent precision rating
Used in high speed and high load applications

Helical Gears
Used for parallel shaft drives,
They have teeth inclined to the axis,
For the same width, their teeth are longer than spur

gears and have higher load carrying capacity,

Their contact ratio is higher than spur gears and they
operate smoother and quieter than spur gears,
Their precision rating is good,
They are recommended for very high speeds and loads,
These gears find wide applications in automotive
gearboxes,
Their efficiency is slightly lower than spur gears,
The helix angle introduces axial thrust on the shaft.

Double Helical Gear (Herringbone)

Used for transmitting power between two parallel

shafts.
Have opposing helical teeth with or without a gap
Two axial thrusts oppose each other and nullify. Hence
the shaft is free from any axial force.
Load capacity is very high,
Manufacturing difficulty makes them costlier than a
single helical gear.
Applications are limited to high capacity reduction
drives like that of cement mills and crushers.

Internal Gear
Used for transmitting power between two parallel shafts,
Teeth on the inner periphery makes the drive very

compact,
The meshing pinion and annular gear are running in the
same direction,
Precision rating is fair.
Useful for high load and high speed application with high
reduction ratio.
Applications of these gears can be seen in planetary gear
drives of automobile automatic transmissions,
They are not recommended for precision meshes
because of design, fabrication, and inspection
limitations.

Rack and Pinion

Rack is a segment of a gear of infinite diameter.
The tooth can be spur or helical
This type of gearing is used for converting rotary
motion into translatory motion or visa versa.

Straight Bevel Gear

Used for transmitting power between intersecting shafts,
Can operate under high speeds and high loads.
Precision rating is fair to good.
They are suitable for 1:1 and higher velocity ratios

They are suitable for right-angle meshes to any other angles.

Their good choice is for right angle drive of particularly low ratios.
Wide application of the straight bevel drives is in automotive differentials,

right angle drives of blenders and conveyors.

Spiral Bevel Gear

Used for transmitting power between intersecting

shafts.
Because of the spiral tooth, the contact length is
more and contact ratio is more.
They operate smoother than straight bevel gears
and have higher load capacity.
But, their efficiency is slightly lower than straight
bevel gear.
Spiral bevel gears are used in an automobile
differential.

Hypoid Bevel Gear

Used for right angle drive in which the axes do not

intersect.
Hypoid bevel gears are similar to spiral bevel but the
pitch surfaces are hyperbolic and not conical.
Pinion can be offset above, or below the gear center,
thus allowing larger pinion diameter, longer life and
smoother mesh, with additional ratios e.g., 6:1, 8:1,
10:1.
This permits the lowering of the pinion axis which is
an added advantage in automobile in avoiding hump
inside the automobile drive line power transmission.
However, the non intersection introduces a
considerable amount of sliding and the drive requires
good lubrication to reduce the friction and wear.
Their efficiency is lower than other two types of bevel
gears.
These gears are widely used in current day automobile
drive line power transmission.

Worm Gear
Consists of a worm, which is very similar to a screw and

a worm gear, which is a helical gear,

Used in right-angle skew shafts,
Engagement occurs without any shock resulting in
quieter operation,
Produces considerable frictional heat,
They need good lubrication for heat dissipation and for
improving the efficiency.
Efficiency of these gears is low anywhere from 40% to
90 %.
High reduction ratios 8 to 400 are possible,
Higher speed ratio gears are non-reversible.
Their precision rating is fair to good.
Used in material handling and transportation machinery,
machine tools, automobiles etc.

Spiral Gear (Crossed Helical)

Also known as crossed helical gears,
They have high helix angle and transmit power between two

non-intersecting non-parallel shafts.

They are used for light load and low speed application such as
instruments, sewing machine etc.
Their precision rating is poor.

Summary

Summary

Gear Failure
Scoring: due to combination of two distinct activities: First, lubrication failure in

the contact region and second, establishment of metal to metal contact,

Wear: kind of tooth damage where in layers of metal are removed more or less

uniformly from the surface,

Pitting of Gears: Pitting is a surface fatigue failure of the gear tooth. It occurs

due to repeated loading of tooth surface and the contact stress exceeding the
surface fatigue strength of the material.

Plastic Flow: Surface deformation takes place due to yielding of surface or

subsurface material.

Tooth Fracture: Tooth fracture is the most dangerous kind of gear failure and

leads to disablement of the drive and frequently to damage of other

components

Gear Noise: The gear noise arises due to several reasons. At the contact point

due to error in the gear profile, surface roughness, impact of tooth and sliding
and rolling friction; bearings and churning of the lubricant.

Law of Gearing
Since there is no sliding, contact speeds must be the same!
In order to maintain constant angular velocity ratio between two

meshing gears, the common normal of the tooth profiles, at all

contact points with in mesh, must always pass through a fixed point
on the line of centers, called pitch point.

Definitions
Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.)

that replaces the toothed gear.

Addendum circle: A circle bounding the ends of the teeth, in a normal

section of the gear.

Dedendum circle: The circle bounding the spaces between the teeth, in

a normal section of the gear.

Clearance: The difference between the Dedendum of one gear and the

addendum of the mating gear.

Backlash: The difference between the tooth thickness of one gear and

the tooth space of the mating gear.

Module
Module (m): Pitch diameter divided by number of teeth. The pitch

diameter is usually specified in millimeters.

m = d/z, = = /

Meshing of Gear Teeth

Pinion: The smallest of any pair of mating gears.

Gear: The largest of the pair is called simply the gear.
Velocity Ratio

Meshing of Gear Teeth

Pitch point: The point of tangency
of the pitch circles of a pair of
mating gears.
Pressure angle : Pressure angle is
the angle between the line of action
and the common tangent
(14.5 20 25 degrees are standar,
14.5 is not used due to its
weakness)
What are the disadvantages of using a high pressure angle?
Does it effect your bearing selection?
Can you make a pressure angle of zero?

Minimum No. of Teeth

Minimum No. of Teeth on pinion to avoid interference for a given gear;
k = addendum/module

In order to have smooth continuous rotation;

STANDARD TOOTH SYSTEMS FOR SPUR GEARS

There are three commonly used pressure angles are 14.5, 20 and 25

Contact ratio: is defined as the maximum number of teeth in contact at any time. Higher the
contact ratio smoother will be gear operation (desirable contact ratio is between 1.4-2.0)

Contact Ratio

Example
In a drive, a velocity ratio of 2.5 with a center
distance of 70 mm is desired.
(a) Determine the pitch diameter of the
gears with 20o full depth involute teeth;
(b) Is there any interference in the system? If
so, how will you avoid it?
(c) Determine the contact ratio,
(d) Find the dedendum, addendum, root
diameters and the tip clearance,

Spur Gear Design Tooth Force Analysis

The normal force F can be resolved into two components;
Ft: transmits power
Fr: does not do any work, tends to push the gears apart.

d is the pitch diameter of the gear in mm

n is the rotating speed in rpm
W power in kW.

Spur Gear Design Tooth Stresses

The highest stress occurs at two locations:
At contact point where the force F acts
2. At the fillet region near the base of the tooth.
1.

Lewis Equation for Tooth Bending Stress

Assumptions made in the derivation are:
1. The full load is applied to the tip of a single tooth in static
condition.
2. The radial component is negligible.
3. The load is distributed uniformly across the full face width.
4. Forces due to tooth sliding friction are negligible.
5. Stress concentration in the tooth fillet is negligible.

How can you measure/calculate Ft?

In SI units we use module

(not circular pitch)

Both Y and y are functions of tooth

shape (but not size) and therefore
vary with the number of teeth in
the gear.

Drawbacks of Lewis Equation

The tooth load in practice is not static. It is dynamic and is

influenced by pitch line velocity.

The whole load is carried by single tooth is not correct.

Normally load is shared by teeth since contact ratio is near to

1.5.
The stress concentration effects at the fillet is not considered.

Modified Lewis Equation for Bending Stress

Modified Lewis Equation should only be used for quick estimations!

(does not include fatigue failure)

Factors Influencing Bending Stess

Spur Gear Tooth Bending Stress (AGMA)

American Gear Manufacturing Association (AGMA) came up with a refined form
of Lewis equation

J = Spur gear geometry factor (includes Lewis form factor Y and a stress
concentration factor based on a tooth fillet radius)

Other Factors
Kv = 1/Kv

Overload Factor

Overload Facor (Ko)

Load Distribution Factor

Premissible Tooth Bending Stress (AGMA)

kf = fatigue stress concentration factor. This factor is included in J factor, hence Kf=1
km = Factor for miscellaneous effects. For idler gears subjected to two way bending, = 1. For
other gears subjected to one way bending, the value is taken from the Fig.7.8. Use km = 1.33
for ut less than 1.4 GPa.

Premissible Tooth Bending Stress (AGMA)

PITTING IN GEAR TEETH

SURFACE FATIGUE STRENGTH (AGMA)

d1= d_pinion

SURFACE FATIGUE STRENGTH (AGMA)

 Face width of wheels is 35 mm.

The gears are supported on less rigid

mountings, less accurate gears and contact

across full face may be assumed.

The ultimate tensile strength of pinion and

gear materials is 420 and 385MPa

respectively.

The gears are made by hobbing process.

Find the tooth bending strength of both

wheels and the maximum power that can

be transmitted by the drive with a factor of
safety 1.5.

From surface durability consideration, find

the maximum power that can be

transmitted by the drive with a factor of
safety 1.2 for a life of 10^8 cycles.

Example-I

EXAMPLE - II
Our aim is to transmit 30 Kw
n1=960 rpm
n2 = 320 rpm
Motor shaft diameter = 30 mm

Design the gears so that;

Life = 10^8 cycles
20 degree full depth involute spur gear

GEARBOX SELECTION

http://www.yr.com.tr/?Page=GSTSelection