MACHINE DESIGN- II

GEARS
 Gears
What we need to Know about them.
1. Type of gears
2. Terminologies or nomenclatures
3. Forces transmitted
4. Design of a gears
 Gears - Basics
• Toothed member that transmits motion and
power from one shaft to another
• Spur and helical gears - parallel shafts
• Bevel and worm gears – non-parallel shafts
• Power transmission efficiency is 98%

• What do we need to know ?

– Gear Geometry – Nomenclature

– Gear Force Analysis
– Gear tooth Bending strength
– Gear tooth Surface fatigue
 Basics
• Requirements:
– Smooth Action
– Constant angular velocity ratio
– Two cylinders in contact with substantial
friction
– will have constant velocity ratio
– can transmit power up to frictional
constrains
– Drawbacks – Low torque capability and
possibility of slip

– Why Teeth ?
• Addition of teeth to transmit higher torque
• Phasing of input and output shafts for timing
and geometry must satisfy requirement for
smooth action
 Type of Gears

• Spurs
• Helical
• Bevel
• And Worm Gears
 Gear Introduction
Spur Gear:
a. Gear principle:
Pressure angle, module, Cycloid, gear ratio etc
b. Gear manufacturing
Conventional, hobbing, CNC, Precision, smooth gear, backlash etc
c. Gear forces & power transmission.
Radial, tangential, reaction force in bearing, Train gear, planetary
gear etc
d. Single stage transmission
Input/output torque, Reducer gear
e. Double stages transmission
Reaction force bearing, reducer, I/O torque etc
f. Triple stages transmission
Three stage reducer compact gear, Force, bearing etc
g. Increaser gear transmission
Gear force, gear design etc
 Helical Gear
a. Basic principle helical gear
• Tangential, radial, axial force, Normal module, helix
angle etc
b. Bearing forces
• Reaction force – bearing, design of bearing, Bending
etc
c. Parallel axis transmission
• Gear ratio, torque, axial force, helix angle
d. Inclined transmission
• Similar screw gear, power force, helix angle etc
e. Double helical transmission
• Two stage helical gear transmission.
f. Multi stages helical transmission
• Two stage spur gear and one helical gear transmission
g. Spherical gear transmission
• Curved gear, hypoid / bevel curved gear.
 Bevel Gear ( see: 1,2)
1. Basic principle bevel gear
2. Bevel gear transmission (radial)
3. Helical bevel gear transmission
4. Spherical bevel gear transmission
5. Multi stages bevel gear
6. Worm gear transmission
7. Hypoid gear transmission
 Differential Gear (see: 1, 2)

1. Basic principle planetary gear

2. Planetary without internal teethed gear
3. Cyclo gear transmission
4. Differential gear in automobile
5. Gear transmission with 5 speeds
6. Gear transmission in “Honda 125”
7. Precision and accuracy of the gear teeth
 Spur Gears

Are used in transmitting torque between parallel

shafts
Spur gear drive with teeth on the outside of a cylinder
and parallel to the cylinder axis
Gear Train
 Helical Gears

Are used in transmitting torques between parallel or non

parallel shafts, they are not as noisy as spur gears
Helical gears

Helical gear drive with

gear teeth cut on a
spiral that wraps
around a cylinder
 Bevel Gears
• Are used to transmit
rotary motion
between intersecting
shafts

Teeth are formed on

conical surfaces, the
teeth could be straight or
spiral.
Bevel gears
 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, 3 or more.
Worm gears
Nomenclature
 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.
Pinion : The smaller gear of a pair in contact
Gear : other one
Pitch diameter : dia. of the pitch circle
Module : Pitch diameter (mm) divided by No. of teeth
Circular pitch: Tooth to tooth distance on the pitch circle or
Tooth thickness + width of the space p= d/N
 Internal Spur Gear System

Addendum: Distance from the pitch Circle to

Addendum : circle=1/P in.
Dedendum: Distance from the pitch circle to
dedendum circle=1.25/P in.
Pitch Circle, theoretical circle upon which all calculation is
based

p, Circular pitch, p the distance from one teeth to the

next, along the pitch circle. p= d/N

m, module = d/N, pitch circle/number of teeth

p= m

P, Diametral Pitch P=N/d, pP= 

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.
How Gear Profile is constructed

A1B1=A1A0, A2B2=2 A1A0 , etc

Involute Tooth Profile
Gear Tooth Pressure Angle
Gear Tooth Terminology
 Contact Ratio
• The average number of teeth in contact (at any
one point) as the gears rotate together

Where a – addendum circle

b – base circle
pb – base pitch = db/N (N – no. of teeth)
db – d cos  & pb – p cos 
rap, rag - addendum radii of the mating pinion and gear
rbp, rbg - base circle radii of the mating pinion and gear

• Greater the contact ratio, smoother and quieter

•CR = 2  at least 2 pairs of teeth are theo. in
contact
 Standard Gear Teeth

Item 20o full depth 20o Stub 25o full depth

Addendum a 1/P 0.8/P 1/P
Dedendum 1.25/P 1/P 1.25/P
Clearance f 0.25/P 0.2/P 0.25/P
Working depth 2/P 1.6/P 2/P
Whole depth 2.25/P 1.8/P 2.25/P
Tooth thickness 1.571/P 1.571/P 1.571/P
Face width 9/P<b<13/P 9/P<b<13/P 9/P<b<13/P
 Gear Trains

n5 N1 N N4
=( )( 3
)( )
n1 N2 N4 N5
 Planetary Gear train
You can get high torque ratio in a smaller space

There are two inputs to the planetary gears, RPM of sun

and Ring, The out put is the speed of the arm.
Example of planetary Gear train

Gear 1, sun , RPM 1200, Number of teeth 20,

Planet Gear , Number of teeth 30

Ring Gear, Rotates RPM 120, and teeth of 80,

¼ horse power, find the speed of the arm and torque on the ring.
Alternatively you may have Certain Out put Torque
requirements
 Transmitted Load
• With a pair of gears or gear sets, Power is
transmitted by the force developed between
contacting Teeth
 These forces have
to be corrected for
dynamic effects ,
we discuss later,
considering AGMA
factors

Ft = Fn cos
Fr = Fn sin  or Fr = Ft tan
Transmitted
2RPM
V = d / 2 = d * d in, RPM rev./min,
60 power hp
V in/sec
V=
dn
12
d in, n rpm, V fpm Pounds feet
Tn SI UNITS:
hp =
63000 Toque lb-in
33000hp
Ft = V fpm
V Mm rpm
F V = Tn
KW = t T= N.m, V m/s, F Newton
1000 9549 Watts
New m/s
 Some Useful Relations
• F=33000hp/V V fpm English system

• Metric System
• KW=(FV)/1000=Tn/9549
• F newton, V m/s, n rpm, T, N.m
• hp= FV/745.7=Tn/7121
 Gear tooth strength- example
Photo elastic pattern of
stresses in a spur gear-tooth

Problem Solution Procedure:

1. Determine fatigue stress for pinion and gear
2. Determine fatigue strength for pinion and gear
3. Equate to find out the unknown quantity
Stress = strength
 Find unknown
 Bending Strength of the a Gear Tooth
(F L)t / 2 6Ft
 = Mc = t 3 =
2
I bt /12 bt

Earlier Stress Analysis of the Gear Tooth was based on

A full load is applied to the tip of a single tooth
The radial load is negligible
The load is uniform across the width
Neglect frictional forces
The stress concentration is negligible

This equation does not consider stress concentration,

dynamic effects, etc.
 Design of gear teeth

Tooth Bending
stress

Note that the radial component of the force Fr ignored, it

puts tooth in compression. Ignoring Fr is thus conservative &
simplifies analysis.
 Design for the Bending Strength of a
Gear Tooth: The AGMA Method
P Ks Km
 = Ft K 0 K v U.S. Customary
b J
1.0 K sK m
 = Ft K 0 K v SI units
bm J
= Bending stress at the root of the tooth

Ft = Transmitted tangential load

K 0= Overload factor
Kv = Velocity factor
P= Diameteral pitch, P
b= Face width
m= Metric modue
Ks = Size factor
Km = Mounting factor
J= Geometry factor
 Your stress should not exceed
allowable stress
St K L
 all =
KT K R
 all = Allowable bending stress

St = Bending Strength

KL = Life factor

KT = Temperature factor

KR = Reliability factor
Overload Factor - Ko
 Dynamic Factor - Kv

-Even with steady loads tooth impact can cause shock loading
-Impact strength depends on quality of the gear and the speed of
gear teeth (pitch line velocity)
-Gears are classified with respect to manufacturing tolerances:
-Qv 3 – 7, commercial quality
-Qv 8 – 12, precision
-Graphs are available which chart Kv for different quality factors
 Load Distribution Factor - Km

-Failure greatly depends on how load is distributed across face

-Accurate mounting helps ensure even distribution
-For larger face widths even distribution is difficult to attain
-Note formula depends on face width which has to be estimated for initial iteration
-Form goal: b < Dp; 6 < b*P < 16
 Reliability Factor - KR

-Adjusts for reliability other than 99%

- KR = 0.658 – 0.0759 ln (1-R) 0.5 < R <0.99
- KR = 0.50 – 0.109 ln (1-R) 0.99 < R < 0.9999
 AGMA Geometry Factor - J

-Updated Lewis Form Factor includes effect of stress concentration at fillet

-Different charts for different pressure angles
-Available for Precision Gears where we can assume load sharing (upper curves)
-HPSTC – highest point of single tooth contact
-Account for meshing gear and load sharing (contact ratio > 1)
-Single tooth contact conservative assumption (bottom curve)
-J = 0.311 ln N + 0.15 (20 degree)
-J = 0.367 ln N + 0.2016 (25 degree)
Bending Strength No. – St,
Fatigue bending strength

-Tabulated Data similar to fatigue strength

-Range given because value depends on Grade
-Based on life of 107 cycles and 99% reliability
 St – Analytical Estimate

-Through hardened steel gears

-Different charts for different manufacturing methods
-Grade 1 – good quality
St = 77.3 HB + 12,800
-Grade 2 – premium quality
St = 102 HB + 16,400
Bending Strength Life Factor- KL

-Adjusts for life goals other

than 107 cycles
-Fatigue effects vary with
material properties and surface
finishes
-KL = 1.6831 N -0.0323 N>3E6

Note: @ 2000 rpm reach 3

million cycles in 1 day of
service
 Gear Types and Efficiency
• Previous calculations were done under
ideal conditions.
Add efficiency in calculation by multiplying
in with ratio

• Spur gears
– Efficiency ~ 95% - 98%
 Gear Types and Efficiency (cont.)
• Chain and Sprockets
– Efficiency ~ 95% - 98%

• Belt and Pulley

– Efficiency ~ 85%-98% (timing belt best)
 Gear Types and Efficiency (cont.)
• Bevel Gears
– Efficiency ~ 90% - 95%

• Worm Gears
– Efficiency ~ 40%-70%