g

shaft to another. Several types of gears are commonly

used and are available as stock items from original
equipment suppliers worldwide. This chapter
introduces various types of gears and gear
transmission and details the design, specification, and
selection of spur gears, in particular, based on the
consideration of failure due to bending using the
Lewis equation

DEBRE BIRHAN UNIVERSITY

COLLEGE OF ENIGNEERING

DEPARTMRT OF MECHAMNICAL ENIGINEERIG

Machin elemen individual assignment

Bores Bode

Student Name Birhani Zenebe

ID 0239

Section B

1
 GEAR DESIGN

Gears are toothed wheels that transmit motion from one shaft to another and
determine the speed, torque, and direction of rotation of machine elements. Gears can
be grouped into two major categories: those that operate in pairs to connect parallel
shafts and those that connect nonparallel shafts. Parallel types include spur and
helical. Nonparallel types include bevel, hypoid, and worm.

1. Spur gears

Figure 1. 1 super gears

Spur gears are a type of cylindrical gear, with shafts that are parallel and coplanar, and
teeth that are straight and oriented parallel to the shafts.

Spur Gears are the simplest type of gear. The calculations for spur gears are also
simple and they are used as the basis for the calculations for other types of gears. This

2
section introduces calculation methods of standard spur gears, profile shifted spur
gears, and linear racks. The standard spur gear is a non-profile-shifted spur gear.

(1) Standard Spur Gear shows the meshing of standard spur gears. The meshing of
standard spur gears means the reference circles of two gears contact and roll with each
other.

Fig. 1.2 The Meshing of Standard Spur Gears

( α=20°, z1=12, z2=24, x1=x2=0 )

Example
No. Item Symbol Formula Gear
Pinion (1)
(2)
1 Module M 3
2 Reference Pressure Angle Α Set Value 20 deg
3 Number of Teeth Z 12 24
(z1 + z2) m /
4 Center Distance A 54.000
2NOTE1
5 Reference Diameter D Zm 36.000 72.000
6 Base Diameter Db d cos α 33.829 67.658
7 Addendum Ha 1.00m 3.000 3.000
8 Tooth Depth H 2.25m 6.750 6.750
9 Tip Diameter Da d + 2m 42.000 78.000
10 Root Diameter Df d – 2.5m 28.500 64.500
note1 : The subscripts 1 and 2 of z1 and z2 denote pinion and gear (2) Profile Shifted
Spur Gear

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Figure 1.1 shows the meshing of a pair of profile shifted gears. The key items in profile
shifted gears are the operating (working) pitch diameters (dw) and the working
(operating) pressure angle (αw). These values are obtainable from the modified center
distance and the following formulas :

1.2.Helical gears

A helical gear is a cylindrical gear in which the teeth flank are helicoid. The helix angle in
reference cylinder is β, and the displacement of one rotation is the lead, The tooth
profile of a helical gear is an involute curve from an axial view, or in the plane
perpendicular to the axis. The helical gear has two kinds of tooth profiles – one is based
on a normal system, the other is based on a transverse system. Pitch measured
perpendicular to teeth is called normal pitch, pn.
And pn divided by π is then a normal module, mn.

The tooth profile of a helical gear with applied normal module,

mn, and normal pressure angle αn belongs to a normal system.

In the axial view, the pitch on the reference is called the transverse pitch, pt . And pt
divided by π is the transverse module, mt.

4
These transverse module and transverse pressure angle αt at are the basic
configuration of transverse system helical gear.
In the normal system, helical gears can be cut by the same gear hob if module and
pressure angle at are constant, no matter what the value of helix angle β.

It is not that simple in the transverse system. The gear hob design must be altered in
accordance with the changing of helix angle β, even when the module and the pressure
angle at are the same.
Obviously, the manufacturing of helical gears is easier with the normal system than with
the transverse system in the plane perpendicular to the axis. When meshing helical
gears, they must have the same helix angle but with opposite hands.

Example
No
Item Symbol Formula
.
Pinion(1) Gear(2)

1 Normal module mn 3

2 Normal pressure angle αn 20 deg

Reference cylinder helix

3 β 30 deg
angle
Set Value
Number of teeth &
4 z 12 (L) 60 (R)
helical hand

Normal coefficient of
5 xn + 0.09809 0
profile shift

Transverse pressure
6 αt 22.79588 deg
angle

5
7 Involute function αwt inv αwt 0.023405

Transverse working
8 αwt Find from involute Function Table 23.1126 deg
pressure angle

Center distance
9 y 0.09744
modification coefficient

10 Center distance a 125.000

11 Reference diameter d 41.569 207.846

12 Base diameter db d cos αt 38.322 191.611

13 Working pitch diameter dw 41.667 208.333

ha1 ( 1 + y – xn2 ) mn
14 Addendum 3.292 2.998
ha2 ( 1 + y – xn1 ) mn

15 Tooth depth h {2.25 + y – ( Xn1 + Xn2 )}mn 6.748

16 Tip diameter da d + 2ha 48.153 213.842

17 Root diameter df da – 2h 34.657 200.346

Fig.1. Fundamental relationship of a helical gear (Right-hand)

6
(1) Normal System Helical Gear
In the normal system, the calculation of a profile shifted helical gear, That is because
meshing of the helical gears in the transverse plane is just like spur gears and the
calculation is similar. shows the calculation of profile shifted helical gears in the normal
system. If normal profile shift coefficientsxn1, xn2 are zero, they become standard
gears.

Helical gear transition

7
 1.3 Bevel Gears

Bevel gears, whose pitch surfaces are cones, are used to drive intersecting axes. Bevel
gears are classified accordingto their type of the tooth forms into Straight Bevel Gear,
Spiral Bevel Gear, Zerol Bevel Gear, Skew Bevel Gear etc. The meshing of bevel gears
means the pitch cone of two gears contact and roll with each other. Let z1 and z2 be
pinionand gear tooth numbers; shaft angle Σ ; and reference cone angles δ1 and δ2 ;
then:

Fig. The reference cone angle of bevel gear

Generally, a shaft angle Σ=90° is most used. Other angles (Figure 4.8) are sometimes
used. Then, it is called “bevelgear in nonright angle drive”. The 90° case is called “bevel
gear in right angle drive”. When Σ=90°, Equation (4.20)becomes :

8
Miter gears are bevel gears with Σ=90° and z1=z2. Their transmission ratio z2 / z1=1. In
the facial view, which is normal to the contact line ofpitch cones, the meshing of bevel
gears appears to be similar to the meshing of spur gears.

1.4 Screw Gears

Screw gearing includes various types of gears used to drive nonparallel and
nonintersecting shafts where the teeth ofone or both members of the pair are of screw
form. Figure 4.14 shows the meshing of screw gears. Two screw gears canonly mesh
together under the conditions that normal modules (mn1) and (mn2) and normal
pressure angles (αn1, αn2) arethe same.

Fig.1. Screw gears of nonparallel and nonintersecting axes

Let a pair of screw gears have the shaft angle Σ and helix angles β1 and β2 :

9
If the screw gears were profile shifted, the meshing would become a little more
complex. Let βw1, βw2 present the workingpitch cylinder ;

3.External gear. 

A gear with teeth on the outside of a cylinder or

cone. Internal gear. A gear with teeth on the inside of a hollow cylinder. Both spur
and helical gears can be made as internal gears. The mating gear for an internal gear
must be an external gear. Bevel gears. Gears with teeth on the outside of a cone-
shaped body. Teeth may be straight or spiral. Normally used at right angles
(perpendicular to each other).Worm gears.  Gear sets in which one member of the pair
has teeth wrapped around a cylinder like screw threads. Normally, this gear, called
the worm, is at a right angle to the mating gear. Worm gears may be cylindrical,
single-enveloping, or double-enveloping. Enveloping designs have curved worm or
gear-tooth shapes to obtain more tooth contact area. Face gears. Gears with teeth on
the end of the cylinder. Hypoid gears. Similar to bevel gears, but they operate on
nonintersecting axes.

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Gears
•
Gears are toothed cylindrical wheels used for
transmitting mechanical power from one rotating
shaft to another. Several types of gears are commonly
used and are available as stock items from original
equipment suppliers worldwide. This chapter
introduces various types of gears and gear
transmission and details the design, specification, and
selection of spur gears, in particular, based on the
consideration of failure due to bending using th

1.5Rack and pinion 

A rack and pinion is a type of linear actuator that comprises a circular gear (the pinion)

engaging a linear gear (the rack), which operate to translate rotational motion into linear
motion. Driving the pinion into rotation causes the rack to be driven linearly. Driving the
rack linearly will cause the pinion to be driven into a rotation. A rack and pinion drive

11
can use both straight and helical gears. Helical gears are preferred due to their quieter
operation and higher load bearing capacity. The maximum force that can be transmitted
in a rack and pinion mechanism is determined by the tooth pitch and the size of the
pinion.

1,5 Miter gears

Miter gears are gears where the axes of the two shafts intersect and the tooth-bearing
faces of the gears themselves are conically shaped. Miter gears are most often
mounted on shafts that are 90 degrees apart and with a gear ratio of 1:1. Miter gears
are divided into 2 types depending of the shape of the teeth. These two types are
straight miter gears and spiral miter gears.

Straight miter gears

In Straight miter gears, the teeth are straight and parallel to the generators of the pitch
cone. Compared with spiral miter gears, straight bevel gears can be made in smaller
sizes. We standardized Straight miter gears as small as module 0.5 in various
materials.
Spiral miter gears
Spiral Miter gears have their teeth formed along piral lines. They are somewhat
analogous to cylindrical type helical gears in that the teeth are angled; however, with
spiral gears the teeth are also curved. Spiral Miter gears have a strength, oscillation and
noise level advantage over straight Miter gears. The disadvantage of Spiral miter gears
is that they produce an axial thrust load. Therefore proper bearing location and firm
support are required for their assembly.

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 1.6 worm and worm gears

A worm gear is a gear consisting of a shaft with a spiral thread that engages with and
drives a toothed wheel. Worm gears are an old style of gear, and a version of one of the
six simple machines. Basically, a worm gear is a screw butted up against what looks
like a standard spur gear with slightly angled and curved teeth.

1.6Internal Gear
Calculations

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 Internal gear is a gear with its teeth cut in the internal surface of a cylinder and
meshes with spur gears .In its manufacturing, because of its shape, the usual ho
bingma chine used in spur gear production cannot be used. Generally it is made
with gear shaper (or gear shaping machine) equipped with a pinion cutter. More
recently, the efficiency of internal gear cutting has been improved by a different
process called skiving.

1). 

14
 

2   

The teble shows the calculation steps.

It will become a standard gear calculation if x1 = x2 = 0.

If the center distance, ax, is given, x1 and x2 would be obtained from the inverse

calculation from item 4 to item 8 of 2. These inverse formulas are in 1

Pinion cutters are often used in cutting internal gears and external gears. The actual
value of tooth depth and root diameter, after cutting, will be slightly different from the

15
calculation. That is because the cutter has a coefficient of shifted profile. In order to get
a correct tooth profile, the coefficient of cutter should be taken into consideration.

1.6.1 Interference In Internal Gears

Three different types of interference can occur with internal gears:
(a) Involute Interference
(b) Trochoid Interference
(c) Trimming Interference
(a) Involute Interference
This occurs between the dedendum of the external gear and the addendum of the
internal gear. It is prevalent when the number of teeth of the external gear is small.
Involute interference can be avoided by the conditions cited below:

where αa2 is the pressure angle seen at a tip of the internal gear tooth.

and αw is working pressure angle:

Equation (5-3) is true only if the outside diameter of the internal gear is bigger
than the base circle:

For a standard internal gear, where α = 20°, Equation (5-5) is valid only if the
number of teeth is z2 > 34.
(b) Trochoid Interference

This refers to an interference occurring at the addendum of the external gear and
the dedendum of the internal gear during recess tooth action. It tends to happen

16
when the difference between the numbers of teeth of the two gears is
small. Equation (5-6) presents the condition for avoiding trochoidal interference.

Here

where αa1 is the pressure angle of the spur gear tooth tip:

In the meshing of an external gear and a standard internal gear α = 20°, trochoid
interference is avoided if the difference of the number of teeth, z1 – z2, is larger
than 9.

(c) Trimming Interference

1.6 This occurs in the radial direction in that it prevents pulling the gears apart.
Thus, the mesh must be assembled by sliding the gears together with an axial
motion. It tends to happen when the numbers of teeth of the two gears are
very close. Equation (5-9) indicates how to prevent this type of interference.

Here

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1.7

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