11 en of gent 1.7. Gear 11.9. Bronching. 11,10, Template mthods Goat angi: 15: Bevel geareutting @ ar shePer proce, 11.13, Rack planine nme pe Hobbing night 6:11.16. Cutting worms and weet wheels, 11.17. Gear finishing — E gear lapping—gear honing. Highlights—Ohjective Tyee Questions—Theoretin! eee aing—genlepping—gone honing. igh 11.1. INTRODUCTION A gear is a whe rust! provided with teeth which mesh with the teeth on another wheel, or on to a rack, so as to ive a positive transmission of motion from one component to another. © Gears constitute the’ m, “ss commonly used device for power transmission or for changing @ power system, 2 They also afford a convenient way of changing Ihe direction of motion. A number of devices such as differentials, transmission gear boxes, Planetary drives ete, used in Many construction machines employ gears as basic components : Power-speed ratios in aking gearé include cast iron, cast steel, structural steel, gu: ‘non-metals” commonly in metal, brass, etc. The used for gear manufacture include and laminated wood, synthetic plastic, fibres Advantages 1. High efficiency, 2. Long service life, 3. High reliability. 4. More compact, 5. Can operate at high speeds, 6. Can be used where precise timing is required, 7. Large power can be transmitted, 8. Constant speed ratio owing to absence of slipping. : 9. Possibility of being applied for a wide range of torques, speeds and speed ratios, 593 ‘Scanned wth CamScanet-tBOOK OF MANUFACTURING 594 ATE is in position is much less than in ay 10. The foree required to hold the Bears in Pee ee eet on the beg friction drive, ‘This results in lowe and efficiency. Disadvantages 1, Special equipment and tools are require , 2. When one wheel gets damaged the whole set up 38 3. Noisy in operation at considerable speeds. .d to manufacture the gears, affected, 11.3. TYPES OF GEARS ‘The different types of gears used are enume! 1. Spur gear. . Helical gear. Bevel gear. |. Worm gear. Rack and pinion. 1. Spur gear. A spur gear is a gear wheel or pinion for trans- mitting motion between two parallel shafts. This is the simplest form of geared drive. The teeth are cast or machined parallel with the axis of rotation of the gear. Normally the teeth are of involute form, Fig. 11.1 illustrates a spur gear drive, consisting of a pinion and a spur wheel, The efficiency of power transmission by these gears is very high and may be as much as 99% in case of high-speed gears with good material and workmanship of construction and good lubrication in operation. Under average conditions, efficiency of 96-98% are commonly attainable. The disadvantages are that they are liable to be more noisy in operation and may wear out and develop backlash more readily than the other types. } 2. Helical gear. Refer to Fig. 11.2. Helical gear is one in SSS which teeth instead, of being parallel with shaft as in ordinary spur K‘mOD»y gears, are inclined. ‘This ensures smooth action and more accurate ' maintenance of velocity ratio. A disadvantage is that the inclination of the t lateral thrust. A method of neutralising this lateral is to use double-helical gears (also known as Herr shown in Fig. 11.3. 3. Bevel gear. Refer to Fig. 11. motion between two shafts which intersect. If the shafts are at right angles and wheels equal in size, they are called mitre gears If ee shafts are not at right angles, they are sometimes called angle bere} gears. Spiral toothed bevel gears are preferred to straight terior bevels in certain applications, because they will ram more smenth and make less noise at high speeds. moothly 4. Worm gear. Refer to Fig. 11.5. Worm non-parallel, non-intersecting shafts which are : One of the gears is called the tuore Te is ccoom an risht angle cd ‘i ‘sential, serew, meshing with the teeth on a gear wheel, called the yoy ated and described briefly below Fig. 11.2. Helical Fig. 11.3. Double eoth sets up a or axial thrust ing bone gears) . A bevel gear transmits Bears connect two ‘Scanned wth CamScanet‘GHAR MANUFACTURING 595 wheel”. The gear ratio is the ratio er ‘No of number of teeth on the wheel to the number of threads on the ges of worm ge ‘m wheel) are oni ‘aring in that high gear ration (.c., ratio of rotational ily obtained. Worm gearing is smooth and quiet. Fig. 11.5. Worm gear. 5. Rack and pinion, assumes the shape of a straij motion into rectilinear motion, Fig. 11.6. Rack and pinion. Refer to Fig. 11.6. A rack is a spur gear of infinite diameter, thus it ight gear. The rack is generally used with a pinion to convert rotary 11.4, FORMS OF GEAR TEETH The most commonly used forms of gear teeth are : 1. Involute. 2. Cycloidal. The involute tooth is derived from the trace of the point on a straight line, which rolls without slipping around a circle, which is the base circle. It could also be defined as the locus of a point on a piece of string which is unwounded from a stationary cylinder. The cycloidal tooth is derived from the curve which is the locus of a point on a circle rolling on the pitch circle of the gear. Here the addendum of the tooth is trace of the point on a circle rolling on outside of pitch circle and this is an epicycloidal curve whereas the dedendum portion of the tooth is the trace of the point on a circle rolling on inside of the pitch circle of the gear and is a hypocycloidal curve. Involute gears are also called straight tooth or spur gears and are mainly used for general purpose in precision engineering. They possess the following advantages : 1. The involute teeth can be generated easily and accurately in gear-cutting machines. 2. All gears having the same pitch and pressure angle work correctly together. 3, The pressure angle is constant. 4. ‘The face and flank of a tooth form a continuous curve. 5. An involute rack has straight teeth. This enables the complex involute form to be gener- ated from a relatively simple cutter. 6. The gears still work currently, even when the pitch circle do not exactly touch, the i velocity ratio remaining constant. A disadvantage is that when pinions with a small number of teeth are used there will be interference between the points of pinion teeth and the teeth on the gear wheel with which they mesh. This is way the teeth are slightly rounded off at the tip. © ‘The eyeloidal gears are not generally used in modern engineering but used for some crude purposes where heavy and impact loads come on the machine. ‘Scanned wth CamScanetA ‘TEXTBOOK OF MANUFACTURING TECHN 596 ‘1 ana n below : Various types of gears and their tooth traces are give! Tooth traces S.No. Gears 1 Spur gear ight lines 2 Helical gear Strnight helices 3 Spiral gear Curved Hines ee ‘ es i Te ‘Tooth traces are straight line generators of cone. It is conical in for 4 Straight bevel re '00 operating on intersecting axes usually at angles. Worm gear pair The work and matings worm wheel have their axes non-parallel non-intersecting. Involute curve : Itis defined as the curve traced by the end of a cord which, being held taut all the time, is being unwrapped from a cylinder. Refer to Fig. 11.7. The line (ABCDB) is the involute to the siven circle, Tangent (FB) equals are (FA). Tangent (GC) equals are (GA). Tangent (HD) equals are (HA) and so on. tis also clear that the tangent to the involute at any point will be perpendicular to the generator at that point. This condi. ~ tion fulfills the requirements of laws of gearing. Further it will be noticed that the shape of the involute curve is entirely dependent upon the diameter of base circle from which the involute ie gener- ated. The curvature of the involute goes on decreasing as the base chele diameter goes on increasing and finally involute becomes Straight line when base circle diameter is infinity. 11.5. GEAR TOOTH TERMINOLOGY o j 3 8 4 @ Base circle ‘Scanned wth CamScanetGUAR MANUTACTURING 597 1, Pitch eylindors, Pitch eylindors of a pair of 4 acura in mesh are the imaginary friction eylinders which voll together without any alip and sive the same velocity yatio ae that of pair of yea 2. Pitch cirel Pressure angle Mt is the imaginary circle most useful in calculations, It may be noted that an infinite “addendum number of pitch circles can be chosen, each associated ‘Dedendum with ite own pressure angle, ‘Clearance 4. Base elrele, It is the circle from which invo- Jute form is generated. Only the base circle on a gear is jived and unalterabs 4, Piteh circle diameter (P.C.D,) or pitch di- ©) amotor (D). It is the diameter of the circle which by Fig. 11.8 pure rolling action would produce the same motion as the toothed gear wheel. In ease of spur gears this is the diameter of a dise which this gear has replaced. ' the most important diameter in gears. ae 5, Cireular pitch (p,). It is the distance measured along the circumference of pitch circle from a point on one tooth to the corresponding point on the next tooth. If 7'is the number of teeth on a wheel, D the pitch diameter the circular pitch (p, is given by pa : wD) where, 2 is the standard term known as module. 6, Diametral pitch (p,). It is the number of tooth of the gear per mm of pitch circle diameter 5 (11.2) mi Pu= Dp (11. 7. Module (m). It is reverse of the diametral pitch, Ratio between the pitch diameter and the number of teeth is known as module (m). m 2 -(11.3) For the purpose of standardisation, gears are available in the following standard module : 0.3 to 0.8mm _in steps of 0.1 mm 1.0 to 5mm _ in steps of 0.25 mm 5to 7mm ___ in steps of 0.5 mm 7to 16mm in steps of 1 mm 20 to 50 mm —_in steps of 2 mm 30 to 45mm —_in steps of 5 mm, 8, Pitch point. It is the point of contact of the two pitch circles of mating gears. 9. Addendum circle or trip cirele. It is a circle concentric with the pitch circle and bounding the outer ends of the teeth. ‘Scanned wth CamScanet598 A TEXTHOOK OF MANUFACTURING TEC 10. Dedendum or root eirele. 11 is a circle concentric with the pitch circle and ben {he bottoms the teeth. In case of a whee having internal teeth-enlled annulus—the dedendun dedendum circles are inside and outside the pitch circle respectively. " 11. Addendum, It is the radial distance between the pitch circle and the addendum, Its standard value is equal to one module. ‘This may be varied to avoid interference probf 12, Dedendum, It is the radial distance between the pitch circle and the dedendum Its standard value is (1 ' 3) module = 1,157 module, 20 13. Clearance. The difference between the dedendum and the addendum is called g clearance. Naturally its standard value = (1.157 module — 1 module) = 0.157 module. : 14. Working depth. It is the sum of the addenda of the two mating gears. 15. Bottom clearance. It is the minimum distance between the tip of a tooth and 0 bottom of its mating space. 16. Blank diameter. The diameter of a gear blank is equal to the pitch circle diameter twice addenda 3 17. Tooth thickness. It is the thickness of the tooth measured on the pitch circle. 18. Tooth space. It is the width of the recess between the two adjacent teeth meas along the pitch circle. 19. Face. The acting or working surface of the addendum is called face. 20. Flank. It is the working surface of the dedendum. 21. Backlash. The difference between tooth space and the tooth thickness is called backlash 22. Pinion. The smaller of the two mating gears is known as pinion and the larger, the whee 23. Top land. It is the surface of top of the gear. 24. Bottom land. It is the surface of the bottom of the tooth space. 25. Whole depth. It is the total depth of tooth space equal to sum of addendum and dedendum and is also equal to the working depth plus clearance 26. Tooth fillet. It is the radius which connects the root circle to the tooth profile. 27. Angle of obliquity or pressure angle. Angle of obliquity or pressure angle is the | angle between the tooth profile where it cuts the pitch eirele and the line joining that point to the centre of the pitch cirele. Jn Fig. 11.9. RPM is the angle of obliquity (@). O and @ are the centres of the gear-wheels, q A and B. PL and PK are the parts of pitch circles which touch at the pitch point P. PM is the common tangent to the pitch circles through P. EPP is “line of action”, or “pressure line” Contact between a tooth on wheel A and a tooth on wheel B takes place on this line ZPF, and the pressure of the one tooth on the other is along this line EPP. This is shown to an enlarged scale in Fig, 11.10, in which tooth F of wheel A is in contact with tooth S of wheel B, at the point 7: 1’ is always on the line EPF. Also, this line always cuts the line at the two tooth profiles at right angles. Tt is because of this that involute teeth satisfy the condition for transmitting motion from wheel A to wheel B with constant velocity ratio, ‘Scanned wth CamScanetGHA MANUACTURING wD Yanosh Yah A Vig, N10, The angle of abliquity determines the nize of the base elreles LD tis 1H, on wi Iutew are drawn to form the tooth profiles. A value uf 144" was for a Soni, tins: eonnsnen vale for the angle of obliquity, but an angle of 20° in now standard and videly wsed. The 20 veth much stronger than the 14%” tooth, and undercutting in yours having 2 small nurnber of teth ts wit xreat, At the name time itn ability to withstand wear, and ite quietness in running, are equal to that obtained with other tooth forms, In Pigs 11.10, Wr OK jus of ba irele) i: yavas circle) OH coy gx Pusan of bane cite) Dy (dia.of Waves circle) OP Ti, (rails of ite D,= 1% eon AMA) 28, Base pitch, It is the are distance measured around the base circle from the origin of the involute on the tooth to the origin of a similar involute on the next woth, Bawe cireumference, Number of teeth mxdia.of have cree Dow ap 7 =o mony (: module m Bawe piteh = 29. Involute function (8). It is found from the fundamental principle of involute, that is the locus of the end of a thread Gmaginary) unwound from the base circle. Mathematically, Involute function 6 = tan 9-9 where, § = Pressure angle, Basic tooth proportions for involute spur gear o aie | ~ ‘Pressure angles | Hem ut! ‘Addendum 4 m m Dedendun 1.25 1.457 ‘ ‘oeth depth 22510 2157 m | Circular teeth thickness mao nm/2 Fillet-radiun am 0167m ‘6 Clearance O25 m 0.157 ‘Scanned wth CamScanet