WELCOME

TO
OUR
PRESENTATION

Acknowledgement

We would like to appreciate and give good

thanks to our instructor Msc Abiyu Solomon
who arranged us in participation of this type
of good knowledge acquiring presentation

Recommendation
The huge problem we faced is shortage of
time for study and arranging all things we
are told to do within the given duration.
Any error in this presentation is the cause of
hurrying to do the presentation
If little more time is given for as we clearly
and gently present this topic in good
manner

INTRODUCTION
This presentation deals about the design
criterion of chain drive and gears.
In gear design we consider different gear
types such as spur gear, bevel gear, helical
gear and worm gear.
We
also try to show their designing
procedure and special materials of them.

Chain Drives

Chain drive is diff. from rope and belt drive

in chain drive there is no slip.
The chains are made up of number of rigid
links which are hinged together by pin joints
in order to provide the necessary flexibility
for wrapping round the driving and driven
wheels.

The toothed wheels are known as sprocket wheels

or simply sprockets.

Advantages and Disadvantages of

Chain Drive over Belt or Rope Drive
Advantages
As no slip takes place during chain drive, hence perfect
velocity ratio is obtained.
Since the chains are made of metal, therefore they occupy
less space in width than a belt or rope drive.
It may be used for both long as well as short distances.
It gives a high transmission efficiency (upto 98 percent).
It gives less load on the shafts.
It has the ability to transmit motion to several shafts by one
chain only.
It transmits more power than belts.
It permits high speed ratio of 8 to 10 in one step.
It can be operated under adverse temperature and
atmospheric conditions

Disadvantages
The production cost of chains is relatively
high.
The chain drive needs accurate mounting
and careful maintenance, particularly
lubrication and slack adjustment.
The chain drive has velocity fluctuations
especially when unduly stretched.

Design Procedure of Chain Drive

First of all, determine the velocity ratio of the
chain drive
Select the minimum number of teeth on the
smaller sprocket or pinion from using standard
table

Find the number of teeth on the larger sprocket

Determine the design power by using the service factor, such
that
Design power = Rated power Service factor
Choose the type of chain, number of strands for the design
power and r.p.m. of the smaller sprocket

Note down the parameters of the chain, such as

pitch, roller diameter, minimum width of roller
etc USING this table

Find pitch circle diameters and pitch line

velocity of the smaller sprocket.

Determine the load (W) on the chain by using the following

relation

Calculate the factor of safety by dividing the breaking load (WB) to

the load on the chain ( W ).

Fix the centre distance between the sprockets

Centre distance between the sprockets,= 30 p
Determine the length of the chain.
L = K.p

GEAR DESIGN

What is gear?
Gear is a toothed machine element
Use to transmit power/motion
Use for short space consideration

Gear types are classified

according to

the position of axes of the shafts.

Parallel,
Intersecting,
Non-intersecting and non-parallel.

the peripheral velocity of the gears.

Low velocity
< 3 m/s
Medium velocity 3 - 15 m / s
High velocity >15 m / s

Cont..

the type of gearing.

External gearing
Internal gearing
Rack and pinion

the position of teeth on the gear

Straight
Inclined
Curved

Nomenclature of gear

Cont

Pitch circle
It is an imaginary circle which by pure rolling action, would give
the same motion as the actual gear.

Cont

Addendum:-the radial distance of a tooth from the pitch circle to

the top of the tooth.
Dedendum:- the radial distance of a tooth from the pitch circle to
the bottom of the tooth.
Addendum circle. It is the circle drawn through the top of the
teeth and is concentric with the pitch circle.
Dedendum circle. the circle drawn through the bottom of the
teeth. It is also called root circle.
Circular pitch. It is the distance measured on the circumference
of the pitch circle from a point of one tooth to the corresponding
point on the next tooth.

pc = D/T
D = Diameter of the pitch circle, and
T = Number of teeth on the wheel

Diametral pitch. It is the ratio of number of teeth to the pitch

circle diameter in millimeters.

Cont

Module. It is the ratio of the pitch circle

diameter in millimeters to the number of
teeth. It is usually denoted by m.
Mathematically, Module, m = D / T

Velocity ratio of gears

Let v1 and v2 be the velocities of the point

Q

Forms of teeth

1. Cycloidal teeth A
cycloid is the curve
traced by a point on
the circumference of a
circle which rolls
without slipping on a
fixed straight line

2. Involute teeth. An
involute of a circle is a
plane curve generated by a
point on a tangent

Gear Materials
The cast iron is widely used for the
manufacture of gears due to its good
wearing properties,
The phosphor bronze is widely used for
worm gears in order to reduce wear of the
worms
The steel is used for high strength gears

Design Considerations for a Gear Drive

In the design of a gear drive, the following data is usually given :
1. The power to be transmitted.
2. The speed of the driving gear,
3. The speed of the driven gear or the velocity ratio, and
4. The centre distance.
The following requirements must be met in the design of a
gear drive :
(a) The gear teeth should have sufficient strength so that
they will not fail under static loading or dynamic loading
during normal running conditions.
(b) The gear teeth should have wear characteristics so that
their life is satisfactory.
(c) The use of space and material should be economical.
(d) The alignment of the gears and deflections of the shafts
must be considered because they effect on the performance
of the gears.
(e) The lubrication of the gears must be satisfactory.

Forces on Gear Tooth

Lewis Equation

the permissible working stress,

w = o Cv
where o = Allowable static stress, and
Cv = Velocity factor.
The values of the velocity factor (Cv) are given as follows :

V is the pitch line velocity

Dynamic Tooth Load

Dynamic load occurs b/c of

Inaccuracies of tooth spacing,
Irregularities in tooth profiles
Deflections of teeth under load.
WD = WT + WI
WD = Total dynamic load,
WT = Steady load due to transmitted torque, and
WI = Increment load due to dynamic action.

The increment load (WI) depends upon the pitch line velocity

For average conditions Buckingham

equation

WD = Total dynamic load in newtons,

WT = Steady transmitted load in newtons,
v = Pitch line velocity in m/s,
b = Face width of gears in mm, and
C = A deformation or dynamic factor in N/mm.

The value of C in N/mm may be determined by using the following

relation

K = A factor depending upon the form of the teeth.

= 0.107, for 14 1/2 full depth involute system.
= 0.111, for 20 full depth involute system.
= 0.115 for 20 stub system
tooth error in action (e) depends upon the pitch line velocity (v) and
the class of cut of the gears.
Values of maximum allowable tooth error in action (e) verses pitch line
velocity, for well cut commercial gears.

Values of tooth error in action (e) verses module.

Static Tooth Load

is obtained by Lewis formula by substituting

flexural endurance limit or elastic limit stress (e)
in place of permissible working stress (w).

the values of flexural endurance limit (e) for different

materials are presented in design data books
For safety, against tooth breakage, the static tooth load (WS)
should be greater than the dynamic load (WD).
For steady loads, WS 1.25 WD
For pulsating loads, WS 1.35 WD
For shock loads, WS 1.5 WD

Wear Tooth Load

Ww = DP.b.Q.K
where Ww = Maximum or limiting load for wear in newtons,
DP = Pitch circle diameter of the pinion in mm,
b = Face width of the pinion in mm,
Q = Ratio factor

K = Load-stress factor

The values of surface endurance

limit (es) are given in the design
databooks

es = Surface endurance limit in MPa

or N/mm2,
= Pressure angle,
EP = Young's modulus for the
material of the pinion in N/mm2, and
EG = Young's modulus for the
material of the gear in N/mm2.

The maximum limiting wear load (Ww) must be greater than the dynamic
load (WD).

Causes of Gear Tooth Failure

Bending failure
Pitting:- The failure occurs when the surface
contact stresses are higher than the
endurance limit of the material.
Scoring :-occurs when excessive heat is
generated when there is an excessive
surface pressure
Abrasive wear
Corrosive wear

Design Procedure for Spur Gears

First of all, the design tangential tooth
load

WT = Permissible tangential tooth

load in newtons,
P = Power transmitted in watts,
v = Pitch line velocity in m / s
D = Pitch circle diameter in metres,
N = Speed in r.p.m., and
CS = Service factor.

Apply the Lewis equation

WT = w.b.pc.y = w.b. m.y

= (o.Cv) b. m.y
(Q w = o.Cv)

The Lewis equation is applied only to the weaker of the two wheels
The product (w y) is called strength factor of the gear.
The face width (b) may be taken as 3 pc to 4 pc (or 9.5 m to 12.5
m) for cut teeth and 2 pc to 3 pc (or 6.5 m to 9.5 m) for cast teeth.
Calculate the dynamic load (WD) on the tooth by using
Buckingham equation
WD = WT + WI

Find the static tooth

load
WS = e.b.pc.y = e.b. m.y
For safety against breakage, WS should be greater than WD.

Finally, find the wear tooth load by using the

relation,
Ww = DP.b.Q.K

Helical Gear design

Terms used in Helical Gears
Helix angle:- It is a constant angle made
by the helices with the
axis of rotation.
Axial pitch. It is the distance, parallel
to the axis, between similar
faces of adjacent teeth.
Normal pitch. It is the distance
between similar faces of adjacent
teeth along a helix on the pitch
cylinders normal to the teeth.
pN = pc cos

Face Width of Helical Gears

Overlap = pc = b tan
WA = WN sin = WT tan

b = Minimum face width, and

m = Module.
In case of double helical or herringbone gears, the
minimum face width
is given by
The maximum face width ranges from 20 m to 30 m.
In single helical gears, the helix angle ranges from 20 to 35,
while for double helical gears, it may be made upto 45.

Formative or Equivalent Number of Teeth for Helical

Gears

TE = T / cos3
T = Actual number of teeth on a helical gear,
and = Helix angle.
Proportions for Helical Gears

Strength of Helical Gears

WT = (o Cv) b. m.y'
WT = Tangential tooth load,
o = Allowable static stress,
Cv = Velocity factor,
b = Face width,
m = Module, and
y' = Tooth form factor or Lewis factor corresponding to
the formative
or virtual or equivalent number of teeth.

The dynamic tooth load on the helical gears is given by

The static tooth load or endurance strength of the tooth is given by

WS = e.b. m.y'
The maximum or limiting wear tooth load for helical gears is given
by

N = Normal pressure angle.

Bevel Gears design

used

for transmitting power at a constant

velocity ratio between two shafts whose axes
intersect at a certain angle

Classification of Bevel
Gears

Mitre gears:- When equal bevel gears

(having equal teeth and equal pitch angles)
connect two shafts whose axes intersect at
right angle
Angular bevel gears :-When the bevel gears
connect two shafts whose axes intersect at an
angle other than a right angle
Crown bevel gears:-When the bevel gears
connect two shafts whose axes intersect at an
angle greater than a right angle and one of
the bevel gears has a pitch angle of 90

Cont.

Internal bevel gears:-When the teeth on

the bevel gear are cut on the inside of the
pitch cone,

Nomenclature of bevel gear

Cont
Pitch cone:-It is a cone containing the pitch
elements of the teeth
Cone centre:-the point where the axes of
two mating gears intersect each other.
Pitch angle:-It is the angle made by the
pitch line with the axis of the shaft. It is
denoted by P.
Cone distance:- It is the length of the pitch
cone element

Cont

Addendum angle:-It is the angle subtended by

the addendum of the tooth at the cone centre

Dedendum angle:It is the angle subtended by the dedendum of

the tooth at the cone centre

Cont..
Face angle:- It is the angle subtended by
the face of the tooth at the cone centre
Root angle:- It is the angle subtended by
the root of the tooth at the cone centre
Back (or normal) cone:- It is an imaginary
cone, perpendicular to the pitch cone at the
end of the tooth.
Back cone distance:- It is the length of
the back cone
Backing:- It is the distance of the pitch
point (P) from the back of the boss, parallel
to the pitch point of the gear

Cont..

Crown height:- It is the distance of the crown

point (C) from the cone centre (O), parallel to
the axis of the gear
Mounting height:- It is the distance of the
back of the boss from the cone centre.
Pitch diameter:- It is the diameter of the
largest pitch circle
Outside or addendum cone diameter:- It is
the maximum diameter of the teeth of the gear.

Cont

Inside or dedendum cone diameter:-

Determination of Pitch Angle for

Bevel Gears

Cont

Proportions for Bevel Gear

Addendum, a = 1 m
Dedendum, d = 1.2 m
Clearance = 0.2 m
Working depth = 2 m
Thickness of tooth = 1.5708 m
where m is the module

Strength of Bevel Gears

The modified form of the Lewis equation for the tangential tooth
load is given as follows

Cont.

For satisfactory operation of the bevel gears the number of teeth in

the pinion must not less than

The static tooth load or endurance strength of the tooth for bevel
gears is given by

The maximum or limiting load for wear for bevel gears is given by

Cont..
Q is based on formative or equivalent number of teeth, such
that

Forces Acting on a Bevel Gear

Cont

The magnitude of the tangential and radial components is

forces are considered to act at the mean radius (Rm).

radial force (WR) acting at the mean radius may be further resolved
into two components, WRH and WR.
axial force acting on the pinion shaft

Worm gear design

used for transmitting power at high velocity

ratios between non-intersecting shafts that
are generally, but not necessarily, at right
angles

of worms
1. Types
Cylindrical

2.

or straight worm

Cone or double enveloping worm

Types of Worm Gears

Straight face worm gear :-it is used for light
service
Hobbed straight face worm gear:-its teeth
are cut with a hob, after which the outer
surface is turned.
Concave face worm gear:-used for all heavy
service and general industrial uses.

Terms used in Worm

Gearing

Axial pitch It is also known as linear pitch

of a worm. It is the distance measured
axially(i.e. parallel to the axis of worm) from
a point on one thread to the corresponding
point on the adjacent thread on the worm
Lead It is the angle between the tangent to
the thread helix on the pitch cylinder andthe
plane normal to the axis of the worm
Lead angle. It is the angle between the
tangent to the thread helix on the pitch
cylinder and the plane normal to the axis of
the worm

Cont

The lead angle () may vary from 9 to 45.

Cont.
For a compact design, the lead angle may be determined by the
following relation, i.e.

where NG is the speed of the worm gear and NW is the speed of

the worm.

Contd.
Recommended values of lead angle and pressure angle

Normal pitch. It is the distance measured along the normal to the

threads between two corresponding points on two adjacent threads of
the worm. Mathematically,
Normal pitch, pN = pa.cos

Cont.
Helix angle It is the angle between the
tangent to the thread helix on the pitch
cylinder and the axis of the worm
W + = 90
Velocity ratio It is the ratio of the speed of
worm (NW) in r.p.m. to the speed of the
worm gear(NG) in r.p.m

Cont

Proportions for Worms

Efficiency of Worm Gearing

empirical relation for the values
of

Strength of Worm Gear

Teeth

Cont

Wear Tooth Load for Worm Gear

The load stress factor is given in design data books

Thermal Rating of Worm

Gearing

The heat dissipating capacity depends upon

Area of the housing (A)
Temperature difference between the housing surface
and surrounding air (t2 t1), and
Conductivity of the material (K).
heat dissipating capacity

Cont
Notes :

The maximum temperature (t2 t1) should

not exceed 27 to 38C
The maximum temperature of the lubricant
should not exceed 60C.
According to AGMA recommendations, the
limiting input power of a plain worm gear unit
from the standpoint of heat dissipation, for
worm gear speeds up to 2000 r.p.m. may be
checked from the following relation.

Cont..

Forces Acting on Worm

Gears

Tangential force on the worm

Axial force or thrust on the worm

Cont
Radial or separating force on the worm

Design of Worm Gearing

In designing a worm and worm gear, the

quantities like the power transmitted,
speed, velocity ratio and the centre
distance between the shafts are usually
given and the quantities such as lead angle,
lead and number of threads on the worm
are to be determined

Cont.

the centre distance

The centre distance may be

expressed in terms of the axial lead
(l), lead angle () and velocity ratio
(V.R.),

Cont..

The lowest point on the curve may be determined mathematically by

differentiating the equation with respect to and equating to zero,
i.e.

THANK YOU!!