GEARS

Gears: Gears are

machine elements that
transmit motion/power by
means of successively
engaging teeth.

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 Power transmission
systems

Belt/Rope Drives - Large center distance of the shafts

Chain Drives - Medium center distance of the shafts

Gear Drives - Small center distance of the shafts

In order to transmit power from one shaft to another
shaft, the projections on one disc and recess on another
disc can be made which can mesh with each other.
This leads to the formation of teeth on both discs and
the discs with the periphery are known as Gears. 2
 Friction
Discs
• In case of rope and belt drives velocity
ratio transmitted cannot be exact due to
slip of rope or belt on the pulley.
• Also due to frictional losses the efficiency
of power transmission in such drives is
less.
• In earlier days friction discs were used for
transmitting the power from one shaft to
another shaft.
• In such a case, the power transmission
capacity depends on the friction between
surfaces of two discs.
• There fore the method of using friction
discs got outdated since it is not suitable
for transmitting power as slip occurs
between the discs.
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Advantages of Gear drives:
 It is a positive drive (no slip) i.e. it transmits exactly
velocity from one shaft to another shaft.
 It can transmit very large power.
 It has high transmission efficiency.
 It requires less space.
 It is reliable.
Disadvantages:
 Manufacturing cost of gear is high, since special
tools and machinery is required for gear
manufacturing.
 Maintenance cost of gear drive is also high due to
lubrication requirements.
 The error in cutting tooth may cause vibrations and
noise during operation.
 It requires precise alignment of shafts. 4
 Type of Gears

• Spurs
• Helical
• Bevel and
• Worm Gears
 Classification of gears
according to shaft axis
Parallel
shaft

Helical Rack and

Spur gears
gears Pinion

Spur Gears:
• Spur gears are used when the axis of the two
shafts are parallel to the axis.
• In helical gears the teeth are at some angle
called helix angle (alpha), with respect to axis
of the shaft. 6
 Spur Gears
These are used in transmitting torque between parallel shafts
1. Gears for
connecting
parallel shafts

Spur Gears: External contact Internal contact

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 Helical Gears
• Helical gears run quieter as compared to spur gears
since the contact between teeth is gradual.
• There fore, transmission of the load is gradual which
results in low impact stresses and reduction in noise.
• For this reason, the helical gears are used for high speed
transmission.
• However the disadvantage of use of helical gear is that
they induce axial thrust in one direction on the bearings.
• The problem of axial thrust in helical gears is eliminated
by use of double helical gears called “Herring-bone
gears”.
• These gears are formed by joining two helical gears of
identical pitch but of opposite hand.
• The axial thrust of these two gears act in opposite
direction, therefore, the effect of axial thrust is nullified.

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 Helical Gears
These are used in transmitting torques between parallel
or non parallel shafts, they are not as noisy as spur
gears.
Helical
gears

Parallel Helical gears Heringbone gears

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 Rack and pinion
• It is a special case of spur gear in
which one gear is having infinite
diameter called “Rack”.
• The rack and pinion is used to
transmit the rotary motion into
reciprocating motion or vice-versa.

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Rack and
Pinion

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 • When power is
Intersecting shaft
required to be
Intersectin transmitted from one
g shaft shaft to another shaft
which are intersecting
to each other then
Bevel
Gears Bevel gears are used.
• Generally, the angle
between two shaft is
Straight Spiral
bevel bevel 900.
gears gears
• Straight bevel gears: In this gears the teeth are formed
straight on the cones, and they are parallel to the axis of
the gear.
• Spiral Bevel gears: In this gears the teeth are formed at14
an angle with respect to its axis. The contact between two
meshing teeth is gradual and smooth from start to end, as
in case of helical gears.
 Gears for connecting
intersecting shafts – Bevel Gears

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 Bevel
gears

Straight bevel gears

Spiral bevel gears

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 Bevel Gears
• Are used to transmit rotary motion
between intersecting shafts

Teeth are formed on

conical surfaces, the teeth
could be straight or spiral.
If the teeth are straight,
those are straight Bevel
gears.
If the teeth are with an
angle those are spiral Bevel
gears.
 Non parallel
and Non Non parallel and Non intersecting shafts
intersecting
shafts

Worm and
Spiral gears
Worm Wheel

• Spiral Gears: These are used to transmit power from one

shaft to another shaft which are nonparallel and non
intersecting.
• Spiral gears are used for low load transmission only since they
have point contact between mating teeth.
• These are also called skew gears or crossed helical gears.
• Worm and worm wheel: These are used to transmit power
from one shaft to another shaft which are non intersecting and
their axis are normally right angles to each other to each other.
Worm and Worm
Wheel

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 Worm Gears
Are used for transmitting motion between non parallel and
non transmitting shafts, Depending on the number of teeth
engaged called single or double. Worm gear mostly used
when speed ratio is quiet high.
 Types of Gears
Spur Gear: generally used to transmit
power between two parallel shafts to
which they are attached.
Internal Gears: are used where the
shafts are parallel and the centers
must be closer together than could
be
achieved with a spur or helical
gearing.
Helical gears : may be used to
connect parallel shafts or shafts
which are at an angle.
Herringbone Gears: on most
installations where it is necessary to
overcome end thrust, such gears are
used.
Bevel Gears: When two shafts are
located at an angle with their axial
lines intersecting at 90O, power is
generally transmitted by means of
bevel gears.
. into linear motion, this may be used.
Miter Gears: when the shafts are at
right angles and the gears are of the
same size, they are called miter
gears.
Angular Bevel Gears: if the axis of
the
shafts intersect at any other angle
apart from 90O, the gears are known
as angular bevel gears.
Hypoid Gears: Modified bevel gears
having helical teeth are known as
hypoid gears. Hypoid gears are used
in automobile drives.
Worm and Worm Gear: When shafts
are at right angles and considerable
reduction in speed is required, worm
and worm gear are used.
Rack and Pinion: When it is
necessary to convert rotary motion
Types of Gears
A) Bevel Gear Transmit power at 90o B)
The Miter gear C) Angular bevel gears
D) Hypoid Gears
 Classification of Gears according
to type of Meshing of gears
a.) Externally meshing gears or External
gears:
 In this type the teeth of gears mesh externally
with each other.
 The larger gear is called Wheel and the smaller
gear is called Pinion.
b.) Internally meshing gears or Internal gears:
 In this gears the teeth of gears mesh internally
with each other.
 In this type larger gear is called annular wheel
and the smaller gear is called pinion.

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 Classification of Gears
according to the peripheral
velocity of the gears
a.) Low velocity gears: The gears
having peripheral velocity less than 3
m/sec.
b.) Medium Velocity gears: The gears
having peripheral velocity between 3
to 15 m/sec.
c.) High velocity gears: The gears
having peripheral velocity more than
15 m/sec.
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 Gear materials
• The material used for the manufacture of gears depends upon the strength and
service conditions like wear, noise etc.
• The gears may be manufactured from metallic or non-metallic materials.
• The metallic gears with cut teeth are commercially obtainable in cast iron, steel
and bronze.
• The non metallic materials like wood, rawhide, compressed paper and synthetic
resins like nylon are used for gears, especially for reducing noise.
• The cast iron is widely used for the manufacture of gears due to its good wearing
properties, excellent machinability and ease of producing complicated shapes by
casting method.
• The cast iron gears with cut teeth may be employed, where smooth action is not
important.
• The steel is used for high strength gears and steel may be plain carbon steel or
alloy steel.
• The steel gears are usually heat treated in order to combine properly the
toughness and tooth hardness.
• The phosphor bronze is widely used for worm gears in order to reduce wear of the
worms which will be excessive with cast iron or steel.

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 Industrial
Applications
Stamping presses

Motorcycle Transmissions

Automotive applications

Special gear box builders

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 Nomenclature

Smaller Gear is Pinion and Larger one is the gear

In most application the pinion is the driver, This reduces speed but it increases
torque.
 Comparision of Gear
drives when compared
with friction drives

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Internal Spur Gear System
Terminol
ogy

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pitch circle, theoretical circle upon which all calculation is based
pc, Circular pitch, p the distance from one teeth to the next, along
the pitch circle. pc=(πd)/T
m, module=d/T (pitch circle/number of teeth)
pc= (π*m)
Diametral Pitch Pd=T/d
Angle between the Line of Action and a line
perpendicular to the Line of Centers.
Angle Φ has the values of 20 or 25 degrees. Angle 14.5
have been also used.
Gear profile is constructed from the base circle. Then
additional clearance are given.
 Gear
Terminology

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Definitions

Module: Ratio of Pitch Diameter to Teeth.

Pinion: The smaller of two meshed gears.

Pitch Circle: The circle, the radius of which is equal to the

distance from the center of the gear to the pitch point.

Diametral pitch: Teeth per millimeter of pitch diameter.

Pitch Point: The point of tangency of the pitch circles of

two meshing gears, where the Line of Centers crosses the
pitch circles.

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Definitions
Pressure Angle: Angle between the Line of Action and
a line perpendicular to the Line of Centers.

Root Circle: The circle that passes through the bottom

of the tooth spaces.

Root Diameter: The diameter of the Root Circle.

Working Depth: The depth to which a tooth extends

into the space between teeth on the mating gear.

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Definitions
Base Circle: The circle from which is generated the
involute curve upon which the tooth profile is based.
Center Distance: The distance between centers of two
gears.
Circular Pitch: Millimeter of Pitch Circle circumference
per tooth.
Addendum: The radial distance between the Pitch
Circle and the top of the teeth.
Backlash: Play between mating teeth.

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Definitions
Circular Thickness: The thickness of the tooth
measured along an arc following the Pitch Circle

Clearance: The distance between the top of a tooth and

the bottom of the space into which it fits on the meshing
gear.

Contact Ratio: The ratio of the length of the Arc of

Action to the Circular Pitch.

Dedendum: The radial distance between the bottom of

the tooth to pitch circle.

Diametral Pitch: Teeth per mm of diameter. 43

Definitions
Face: The working surface of a gear tooth, located
between the pitch diameter and the top of the tooth.

Face Width: The width of the tooth measured parallel

to the gear axis.

Flank: The working surface of a gear tooth, located

between the pitch diameter and the bottom of the teeth

Land: The top surface of the tooth.

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Formulae
 D
Circular pitch  p c  
Diametral pitch T
 T 
Diametral pitch  p d   
Circular pitch D p c
Teeth
Pitch diameter 
Diametral pitch
Teeth X Circular pitch


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 Law of Gearing
Therefore, velocity ratio

1 O2 P
 1
2 O1 P
Point P is very important to the velocity
ratio, and it is called the pitch point.

Pitch point divides the line between the
line of centers and its position decides
the velocity ratio of the two teeth.
In other words, the common normal at
the point of contact between a pair of
teeth must always pass through pitch
point.
The above expression is the
fundamental law of gear-tooth action
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Conjugate Profiles

If the tooth profiles of a pair of gears

are so designed that a constant
velocity is maintained during
operation, then the gears are said to
have conjugate action and this kind 
of tooth profiles are said to be
conjugate profiles.

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 Gear
Cutting
• Most gears cut on a milling machine are
generally used to repair or replace a gear
that has been broken or lost or is no longer
carried in inventory. Industry generally mass-
produce gears on special machines designed
for this purpose. The most common types of
gear–generating machines are the gear-
shaping and gear-hobbing machines.
 Gear Tooth Profiles
Although many tooth
shapes are possible for
which a mating tooth
could be designed to
satisfy the fundamental
law, only two are in
general use:
1.)Cycloidal profiles
and
2.) Involute profiles.
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S.N Involute tooth gears Cycloid tooth gears
o.
1. The profile of involute The profile of cycloidal
gears is the single gears is double curvature
curvature. i.e. epicycloid and
hypocycloid
2. The pressure angle from The pressure angle varies
start of engagement of from start of engagement
teeth to the end of to end of engagement,
engagement remains which results into less
constant, which results smooth running.
into smooth running.
3. Manufacturing of involute Manufacturing of cycloidal
gears is easy due to single gears is difficult due to
curvature of tooth profile. double curvature of tooth
profile.
4. The involute gears have The cycloidal gears do not
interference problem. have interference problem.
5. More wear of tooth Less wear as convex face
surface. engages with concave flank.
6. The strength of involute The strength of cyloidal
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teeth is less due to radial teeth is comparatively more
 System of Gear Teeth
The following four systems of gear teeth are commonly used
in practice:
1. 14 ½O Composite system

2. 14 ½O Full depth involute system

3. 20O Full depth involute system

4. 20O Stub involute system

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 System of Gear Teeth
1.) The 14½O composite system is used for general purpose
gears.
 This type of profile is made with circular arcs at the top and
bottom portion middle portion is a straight line.
 The straight portion corresponds to involute profile and the
circular arc portion corresponds to the cycloidal profile.
 The teeth are produced by formed milling cutters or hobs.
2.) The tooth profile of the 14½O full depth involute system was
developed using gear hobs for spur and helical gears.
 The whole profile corresponds to the involute profile.
 Therefore manufacturing of such profile is easy but they have
interference problem. 52
 System of Gear Teeth
3.) The tooth profile of the 20o full depth involute system
may be cut by hobs.
The increase of the pressure angle from 14½o to 20o
results in a stronger tooth, because the tooth acting as a
beam is wider at the base.
This type of gears also have interference problem if the
number of teeth is less.
4.) The 20o stub involute system has a strong tooth to
take heavy loads.
The problem of interference in 200 full depth involute
system is minimized by removing extra addendum of the
gear tooth which causes interference, this kind of modified
tooth profile is “Stub tooth Profile”.
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 Causes of Gear Tooth
Failure
1. Bending failure.
Every gear tooth acts as a cantilever. If the total repetitive dynamic load
acting on the gear tooth is greater than the beam strength of the gear
tooth, then the gear tooth will fail in bending, i.e. the gear tooth will
break.
In order to avoid such failure, the module and face width of the gear is
adjusted so that the beam strength is greater than the dynamic load.
2. Pitting.
It is the surface fatigue failure which occurs due to many repetition of
contact
stresses. The failure occurs when the surface contact stresses are higher
than the endurance limit of the material. The failure starts with the
formation of pits which continue to grow resulting in the rupture of the
tooth surface.
In order to avoid the pitting, the dynamic load between the gear tooth
should be less than the wear strength of the gear tooth.

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3. Scoring: The excessive heat is generated when there is an excessive
surface pressure, high speed or supply of lubricant fails.
This type of failure can be avoided by properly designing the parameters
such as speed, pressure and proper flow of the lubricant, so that the
temperature at the rubbing faces is within the permissible limits.
4. Abrasive wear: The foreign particles in the lubricants such as dirt,
dust or burr enter between the tooth and damage the form of tooth.
This type of failure can be avoided by providing filters for the lubricating
oil or by using high viscosity lubricant oil which enables the formation
of thicker oil film and hence permits easy passage of such particles
without damaging the gear surface.
5. Corrosive wear: The corrosion of the tooth surfaces is mainly caused
due to the presence of corrosive elements such as additives present
in the lubricating oils. In order to avoid this type of wear, proper anti-
corrosive additives should be used.

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