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4.0 Gears:
Introduction: The slip and creep in the belt or rope drives is a common phenomenon, in the
transmission of motion or power between two shafts. The effect of slip is to reduce the
velocity ratio of the drive. In precision machine, in which a definite velocity ratio is
importance (as in watch mechanism, special purpose machines..etc), the only positive drive
is by means of gears or toothed wheels.
When one of the discs is rotated, the other disc will be rotate as long as the tangential force
exerted by the driving disc does not exceed the maximum frictional resistance between the
two discs. But when the tangential force exceeds the frictional resistance, slipping will take
place between the two discs. Thus the friction drive is not positive a drive, beyond certain
limit.
Gears are machine elements that transmit motion by means of successively engaging teeth.
The gear teeth act like small levers. Gears are highly efficient (nearly 95%) due to primarily
rolling contact between the teeth, thus the motion transmitted is considered as positive.
Gears essentially allow positive engagement between teeth so high forces can be transmitted
while still undergoing essentially rolling contact. Gears do not depend on friction and do best
when friction is minimized.
1
Hoists and Cranes Commercial and Military Military offroad vehicles
operations
Automotive prototype and Low volume automotive Stamping presses
reproduction production
Diesel engine builders Special gear box builders Many different special
machine tool builders
4.1 Gear Classification: Gears may be classified according to the relative position of the
axes of revolution. The axes may be
1. Spur gears: Spur gears are the most common type of gears. They have straight teeth,
and are mounted on parallel shafts. Sometimes, many spur gears are used at once to
create very large gear reductions. Each time a gear tooth engages a tooth on the other
gear, the teeth collide, and this impact makes a noise. It also increases the stress on the
gear teeth. To reduce the noise and stress in the gears, most of the gears in your car are
helical.
Spur gears (Emerson Power Transmission Corp)
Spur gears are the most commonly used gear type. They are characterized by teeth, which
are perpendicular to the face of the gear. Spur gears are most commonly available, and are
generally the least expensive.
• Limitations: Spur gears generally cannot be used when a direction change between the
two shafts is required.
Iinternal contact
2. Parallel helical gears: The teeth on helical gears are cut at
an angle to the face of the gear. When two teeth on a helical
gear system engage, the contact starts at one end of the tooth
2
and gradually spreads as the gears rotate, until the two teeth are in full engagement.
Helical gears
(EmersonPower Transmission Corp) Herringbone gears
(or double-helical gears)
This gradual engagement makes helical gears operate much more smoothly and quietly than
spur gears. For this reason, helical gears are used in almost all car transmission.
Because of the angle of the teeth on helical gears, they create a thrust load on the gear when
they mesh. Devices that use helical gears have bearings that can support this thrust load.
One interesting thing about helical gears is that if the angles of the gear teeth are correct,
they can be mounted on perpendicular shafts, adjusting the rotation angle by 90 degrees.
Helical gears to have the following differences from spur gears of the same size:
Perhaps the most well-known application of a rack is the rack and pinion steering system
used on many cars in the past
Gears for connecting intersecting shafts: Bevel gears are useful when the direction of
a shaft's rotation needs to be changed. They are usually mounted on shafts that are 90
degrees apart, but can be designed to work at other angles as well.
3
The teeth on bevel gears can be straight, spiral or hypoid. Straight bevel gear teeth actually
have the same problem as straight spur gear teeth, as each tooth engages; it impacts the
corresponding tooth all at once.
Just like with spur gears, the solution to this problem is to curve the gear teeth. These spiral
teeth engage just like helical teeth: the contact starts at one end of the gear and progressively
spreads across the whole tooth.
Neither parallel nor intersecting shafts: Helical gears may be used to mesh two shafts
that are not parallel, although they are still primarily use in parallel shaft applications. A
special application in which helical gears are used is a crossed gear mesh, in which the
two shafts are perpendicular to each other.
Crossed-helical gears
4
worm gears to have reductions of 20:1, and even up to 300:1 or greater.
Many worm gears have an interesting property that no other gear set has: the worm can
easily turn the gear, but the gear cannot turn the worm. This is because the angle on the
worm is so shallow that when the gear tries to spin it, the friction between the gear and
the worm holds the worm in place.
5
Figure 4-4 Spur Gear
6
Terminology:
Addendum: The radial distance between the Pitch Circle and the top of the teeth.
Arc of Action: Is the arc of the Pitch Circle between the beginning and the end of the
engagement of a given pair of teeth.
Arc of Approach: Is the arc of the Pitch Circle between the first point of contact of the gear
teeth and the Pitch Point.
Arc of Recession: That arc of the Pitch Circle between the Pitch Point and the last point of
contact of the gear teeth.
Base Circle: The circle from which is generated the involute curve upon which the tooth
profile is based.
Chordal Addendum: The distance between a chord, passing through the points where the
Pitch Circle crosses the tooth profile, and the tooth top.
Chordal Thickness: The thickness of the tooth measured along a chord passing through the
points where the Pitch Circle crosses the tooth profile.
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.
7
Dedendum: The radial distance between the bottom of the tooth to pitch circle.
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
Gear: The larger of two meshed gears. If both gears are the same size, they are both called
"gears".
Line of Action: That line along which the point of contact between gear teeth travels,
between the first point of contact and the last.
Pitch Circle: The circle, the radius of which is equal to the distance from the center of the
gear to the pitch point.
Pitch Point: The point of tangency of the pitch circles of two meshing gears, where the Line
of Centers crosses the pitch circles.
Pressure Angle: Angle between the Line of Action and a line perpendicular to the Line of
Centers.
Profile Shift: An increase in the Outer Diameter and Root Diameter of a gear, introduced to
lower the practical tooth number or acheive a non-standard Center Distance.
Root Circle: The circle that passes through the bottom of the tooth spaces.
Working Depth: The depth to which a tooth extends into the space between teeth on the
mating gear.
8
4.2 Gear-Tooth Action
O1 N 1 1 = O2 N 2 2 (4.1)
or
1 O2 N 2
= (4.2) Figure 5-2 Two gearing tooth profiles
2 O1 N1
We notice that the intersection of the tangency N1N2 and the line of center O1O2 is point
P, and from the similar triangles,
1 O2 P
= (4.4)
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. The above expression is the fundamental law of gear-tooth action.
9
From the equations 4.2 and 4.4, we can write,
1 O2 P O2 N 2
= = (4.5)
2 O1 P O1 N1
which determines the ratio of the radii of the two base circles. The radii of the base circles is
given by:
O1 N1 O2 N 2 O1 N1 + O2 N 2
O1O2 = O1 P + O2 P = + = (4.7 )
cos cos cos
where is the pressure angle or the angle of obliquity. It is the angle which the common
normal to the base circles make with the common tangent to the pitch circles.
For a constant velocity ratio, the position of P should remain unchanged. In this case, the
motion transmission between two gears is equivalent to the motion transmission between
two imagined slip-less cylinders with radius R1 and R2 or diameter D1 and D2. We can get
two circles whose centers are at O1 and O2, and through pitch point P. These two circles are
termed pitch circles. The velocity ratio is equal to the inverse ratio of the diameters of pitch
circles. This is the fundamental law of gear-tooth action.
The fundamental law of gear-tooth action may now also be stated as follow (for gears with
fixed center distance)
A common normal (the line of action) to the tooth profiles at their point of contact must, in
all positions of the contacting teeth, pass through a fixed point on the line-of-centers called
the pitch point
Any two curves or profiles engaging each other and satisfying the law of gearing are
conjugate curves, and the relative rotation speed of the gears will be constant(constant
velocity ratio).
10
4.2.3 Conjugate Profiles
To obtain the expected velocity ratio of two tooth profiles, the normal line of their profiles
must pass through the corresponding pitch point, which is decided by the velocity ratio. The
two profiles which satisfy this requirement are called conjugate profiles. Sometimes, we
simply termed the tooth profiles which satisfy the fundamental law of gear-tooth action the
conjugate 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: the cycloidal and involute profiles.
The involute has important advantages; it is easy to manufacture and the center distance
between a pair of involute gears can be varied without changing the velocity ratio. Thus
close tolerances between shaft locations are not required when using the involute profile. The
most commonly used conjugate tooth curve is the involute curve. (Erdman & Sandor).
conjugate action : It is essential for correctly meshing gears, the size of the teeth ( the
module ) must be the same for both the gears.
Another requirement - the shape of teeth necessary for the speed ratio to remain constant
during an increment of rotation; this behavior of the contacting surfaces (ie. the teeth flanks)
is known as conjugate action.
The following examples are involute spur gears. We use the word involute because the
contour of gear teeth curves inward. Gears have many terminologies, parameters and
principles. One of the important concepts is the velocity ratio, which is the ratio of the rotary
velocity of the driver gear to that of the driven gears.
11
Note: We have not defined the term instantaneous center previously. The instantaneous
center or instant center is defined in two ways.
1. When two bodies have planar relative motion, the instant center is a point on one body
about which the other rotates at the instant considered.
2. When two bodies have planar relative motion, the instant center is the point at which the
bodies are relatively at rest at the instant considered.
3. The normal at any point of an involute is tangent to the base circle. Because of the
property (2) of the involute curve, the motion of the point that is tracing the involute is
perpendicular to the line at any instant, and hence the curve traced will also be
perpendicular to the line at any instant.
Cycloidal profile:
Epicycliodal Profile:
12
Hypocycliodal Profile:
• It is easy to manufacture and the center distance between a pair of involute gears can
be varied without changing the velocity ratio. Thus close tolerances between shaft
locations are not required. The most commonly used conjugate tooth curve is the
involute curve. (Erdman & Sandor).
2. In involute gears, the pressure angle, remains constant between the point of tooth
engagement and disengagement. It is necessary for smooth running and less wear of gears.
But in cycloidal gears, the pressure angle is maximum at the beginning of engagement,
reduces to zero at pitch point, starts increasing and again becomes maximum at the end of
engagement. This results in less smooth running of gears.
3. The face and flank of involute teeth are generated by a single curve where as in cycloidal
gears, double curves (i.e. epi-cycloid and hypo-cycloid) are required for the face and flank
respectively. Thus the involute teeth are easy to manufacture than cycloidal teeth.
In involute system, the basic rack has straight teeth and the same can be cut with simple
tools.
1. Since the cycloidal teeth have wider flanks, therefore the cycloidal gears are stronger than
the involute gears, for the same pitch. Due to this reason, the cycloidal teeth are preferred
specially for cast teeth.
2. In cycloidal gears, the contact takes place between a convex flank and a concave surface,
where as in involute gears the convex surfaces are in contact. This condition results in less
wear in cycloidal gears as compared to involute gears. However the difference in wear is
negligible
13
3. In cycloidal gears, the interference does not occur at all. Though there are advantages of
cycloidal gears but they are outweighed by the greater simplicity and flexibility of the
involute gears.
3. The involute tooth form of gears is insensitive to the centre distance and depends only on
the dimensions of the base circle.
4. The radius of curvature of an involute is equal to the length of tangent to the base circle.
5. Basic rack for involute tooth profile has straight line form.
6. The common tangent drawn from the pitch point to the base circle of the two involutes is
the line of action and also the path of contact of the involutes.
7. When two involutes gears are in mesh and rotating, they exhibit constant angular velocity
ratio and is inversely proportional to the size of base circles. (Law of Gearing or conjugate
action)
The following four systems of gear teeth are commonly used in practice:
1. 14 ½O Composite system
It is stronger but has no interchangeability. The tooth profile of this system has cycloidal
curves at the top and bottom and involute curve at the middle portion.
The tooth profile of the 14½O full depth involute system was developed using gear hobs for
spur and helical gears.
14
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.
The 20o stub involute system has a strong tooth to take heavy loads.
Involutometry
Addendum Circle
Pitch Circle
C
B
r
ra E
F
Gear
Base Circle
O
The study of the geometry of the involute profile for gear teeth is called involumetry.
Consider an involute of base circle radius ra and two points B and C on the involute as
shown in figure. Draw normal to the involute from the points B and C. The normal BE and
CF are tangents to the Base circle.
Let
and
Arc AF = Length CF
ArcAE BE
AOE = = = tan b
OE OE
AOB = AOE − b = tan b − b
Inv.b = tan b − b
Expression (tan b − b )is
called involute function
Similarly:
ArcAF BE
AOF = = = tan c
OF OF
AOC = AOF − c = tan C − C
Inv.c = tan c − c
At the po int B
tb
AOD = AOB +
2rb
tb
= tan b − b +
2rb
At the po int C
tc
AOD = AOC +
2rb
tc
= tan c − c +
2rc
16
Equating the above equations :
tb t
tan b − b + = tan c − c + c
2rb 2rc
tb t
inv. b + = inv.c + c
2rb 2rc
t
tc = inv.b − inv. c + b 2rc
2rb
= tooth thickness at C
Using this equation and knowing tooth thickness at any point on the tooth, it is possible to
calculate the thickness of the tooth at any point
Path of contact:
O2
Wheel Base Circle
RA
R
N
Pitch
L Circle
K P Addendum
Circles
M
r Pitch
Circle
ra
Base Circle
O1 Pinion
Consider a pinion driving wheel as shown in figure. When the pinion rotates in clockwise,
the contact between a pair of involute teeth begins at K (on the near the base circle of pinion
or the outer end of the tooth face on the wheel) and ends at L (outer end of the tooth face on
the pinion or on the flank near the base circle of wheel).
MN is the common normal at the point of contacts and the common tangent to the base
circles. The point K is the intersection of the addendum circle of wheel and the common
tangent. The point L is the intersection of the addendum circle of pinion and common
tangent.
The length of path of contact is the length of common normal cut-off by the addendum
circles of the wheel and the pinion. Thus the length of part of contact is KL which is the sum
of the parts of path of contacts KP and PL. Contact length KP is called as path of approach
and contact length PL is called as path of recess.
17
ra = O1L = Radius of addendum circle of pinion,
and
and
and
KN = (O2 K )2 − (O2 N )2
= (RA ) − R 2 cos 2
2
PN = O2 P sin = R sin
Path of approach: KP
KP = KN − PN
= (RA ) − R 2 cos 2 − R sin
2
ML = (O1L )2 − (O1M )2
= (ra )2 − r 2 cos 2
MP = O1 P sin = r sin
Path of recess: PL
PL = ML − MP
= (r ) − r 2 cos 2 − r sin
2
Length of path of contact = KL a
KL = KP + PL
= (RA )2 − R 2 cos2 + (ra )2 − r 2 cos2 − (R + r )sin
18
Arc of contact: Arc of contact is the path traced by a point on the pitch circle from the
beginning to the end of engagement of a given pair of teeth. In Figure, the arc of contact is
EPF or GPH.
O2
Wheel
RA
R
N
L Pitch
E F Circle
Gear
Profile P Addendum
G H
K Circles
M
r Pitch
Circle
ra
Base Circle
O1 Pinion
Considering the arc of contact GPH.
The arc GP is known as arc of approach and the arc PH is called arc of recess. The angles
subtended by these arcs at O1 are called angle of approach and angle of recess respectively.
Lenght of path of approach KP
Length of arc of approach = arc GP = =
cos cos
The contact ratio or the number of pairs of teeth in contact is defined as the ratio of the
length of the arc of contact to the circular pitch.
Length of the arc of contact
Mathematically, Contat ratio =
PC
Where: PC = Circular pitch = m and m = Module.
19
Number of Pairs of Teeth in Contact
Continuous motion transfer requires two pairs of teeth in contact at the ends of the path
of contact, though there is only one pair in contact in the middle of the path, as in Figure.
The average number of teeth in contact is an important parameter - if it is too low due to the
use of inappropriate profile shifts or to an excessive centre distance.The manufacturing
inaccuracies may lead to loss of kinematic continuity - that is to impact, vibration and noise.
The average number of teeth in contact is also a guide to load sharing between teeth; it is
termed the contact ratio
PITCH LINE
Pc
a
h
T b
c
RACK
Base Circle
PINION
PITCH LINE
c 20
RACK
Let
= Pressure angle
a = Addendum of rack
AP a
sin = = (1)
EP EP
a
Path of approach = EP = ( 2)
sin
Path of recess = PF = NF − NP (3)
From triangle O1 NP :
NP = O1 P sin = r sin
From triangle O1NF:
O1 N = O1 P cos = r cos
( ) = (r )
1 1
NF = O1 F 2 − O1 N 2 2
a
2
− r 2 cos 2 2
( )
1
Path of racess = PF = ra2 − r 2 cos 2 2 − r sin
Path of length of contact = EF = EP + PF
( )
1
a
= + ra2 − r 2 cos 2 2 − r sin
sin
Exercise problems refer presentation slides
O2 Wheel
Base Circle
RA
R
N
L Pitch
Circle
P Addendum
K Circles
M
r Pitch
Circle
ra 21
Base Circle
O1 Pinion
Figure shows a pinion and a gear in mesh with their center as O1andO2 respectively. MN is
the common tangent to the basic circles and KL is the path of contact between the two
mating teeth.
Consider, the radius of the addendum circle of pinion is increased to O1N, the point of
contact L will moves from L to N. If this radius is further increased, the point of contact L
will be inside of base circle of wheel and not on the involute profile of the pinion.
Similarly, if the radius of the addendum circles of the wheel increases beyond O2M, then the
tip of tooth on wheel will cause interference with the tooth on pinion. The points M and N
are called interference points.
Interference may be avoided if the path of the contact does not extend beyond interference
points. The limiting value of the radius of the addendum circle of the pinion is O1N and of
the wheel is O2M.
The interference may only be prevented, if the point of contact between the two teeth is
always on the involute profiles and if the addendum circles of the two mating gears cut the
common tangent to the base circles at the points of tangency.
When interference is just prevented, the maximum length of path of contact is MN.
22
3. Centre distance may be increased. It leads to increase in pressure angle.
4. By tooth correction, the pressure angle, centre distance and base circles remain unchanged,
but tooth thickness of gear will be greater than the pinion tooth thickness.
The pinion turns clockwise and drives the gear as shown in Figure.
Points M and N are called interference points. i.e., if the contact takes place beyond M and
N, interference will occur.
The limiting value of addendum circle radius of pinion is O1N and the limiting value of
addendum circle radius of gear is O2M. Considering the critical addendum circle radius of
gear, the limiting number of teeth on gear can be calculated.
Let
Ф = pressure angle
m = module
O2
Wheel Base Circle
RA
R
N
L Pitch
Circle
P Max.
K Addendum
M Circles
r Pitch
Circle
ra
Base Circle
O1 Pinion
aw = Addendum constant of gear (or) wheel
23
aw. m = Addendum of gear ap. m = Addendum of pinion
O1 N 2 = O1 P 2 + NP 2 − 2 O1 P PN cos O1 PN
= r 2 + R 2 sin 2 − 2 r R sin cos (90 + )
= r 2 + R 2 sin 2 + 2 r R sin 2
R 2 sin 2 2 R sin 2 2 RR 2
= r 2 1 + + = r 1 + + 2 sin
rr
2
r r
( PN = O2 P sin = R sin )
1 1
RR 2 mt T T 2
O1 N = r 1 + + 2 sin 2 = 1 + + 2 sin 2
Addendum of the pinion= Or1Nr- O1P 2 tt
1
mt T T 2 2 mt
a pm = +
t t
1 + 2 sin −
2 2
1
=
mt 1 + T T 2 2
+ 2 sin − 1
2 t t
1 + G (G + 2 ) sin 2
2 −1
The equation gives minimum number of teeth required on the pinion to avoid interference.
From triangle O2MP, applying cosine rule and simplifying, The limiting radius of wheel addendum
circle:
1
rr 2
O2 M = R 1 + + 2 sin 2
RR
1
mT t t 2 2
= 1 + T T + 2 sin
2
O2
Wheel Base Circle
RA
R
N
L Pitch
Circle
P Max.
K Addendum
M Circles
r Pitch
Circle
ra
Base Circle
O1 Pinion
25
1
mT
1 + + 2 sin − 1
t t 2
aw m = 2
2 T T
1
T t t 2
aw = 1 + + 2 sin 2 − 1
2 T T
2aW
T =
1
1 1
1 + + 2 sin 2 − 1
2
G G
The equation gives minimum number of teeth required on the wheel to avoid interference.
Minimum number of teeth on the pinion for involute rack to avoid Interference
PITCH LINE Pc
a
h
RACK T b
PINION
PITCH LINE L
M
H
P
K
RACK c
Let
26
t = Minimum number of teeth on the pinion
= Pressure angle
The straight profiles of the rack are tangential to the pinion profiles at the point of contact
and perpendicular to the tangent PM. Point L is the limit of interference.
Backlash:
The gap between the non-drive face of the pinion tooth and the adjacent wheel tooth is
known as backlash.
If the rotational sense of the pinion were to reverse, then a period of unrestrained pinion
motion would take place until the backlash gap closed and contact with the wheel tooth re-
established impulsively.
Backlash is the error in motion that occurs when gears change direction. The term "backlash"
can also be used to refer to the size of the gap, not just the phenomenon it causes; thus, one
could speak of a pair of gears as having, for example, "0.1 mm of backlash."
A pair of gears could be designed to have zero backlash, but this would presuppose
perfection in manufacturing, uniform thermal expansion characteristics throughout the
system, and no lubricant.
Therefore, gear pairs are designed to have some backlash. It is usually provided by reducing
the tooth thickness of each gear by half the desired gap distance.
In the case of a large gear and a small pinion, however, the backlash is usually taken entirely
off the gear and the pinion is given full sized teeth.
27
Backlash can also be provided by moving the gears farther apart. For situations, such as
instrumentation and control, where precision is important, backlash can be minimised
through one of several techniques.
Standard
(cutting)
O2 O2
Pitch Circle
RA R' Wheel
Wheel
R R Base Circle
N N'
'
Standard
(cutting)
P c P Pitch Circle
c' Operating
M Pitch Circle
r
ra M'
Standard Pinion ' r Standard
(cutting) r' (cutting)
O1
Pitch Circle Pitch Circle
Pinion Base Circle
O1
Figure a c Figure b
Let
Let
28
H = tooth thickness of gear on standard pitch circle
B = Backlash
Involute gears have the invaluable ability of providing conjugate action when the gears'
centre distance is varied either deliberately or involuntarily due to manufacturing and/or
mounting errors.
r R c
= =
r ' R' c'
c' cos ' = c cos
cos
c' = c
cos '
cos cos
Now c = c'−c = c − c = c − 1
cos ' cos '
On the operating pitch circle:
Operating pitch = sum of tooth thickness + Backlash
p' = h'+ H '+ B (1)
By involutometry :
h
h' = 2r ' inv. − inv. '+
2r
Substituting h’ and H’ in the equation (1): h
H ' = 2 R' inv. − inv. '+
2 R
h h
p' = 2r ' inv. − inv. '+ + 2 R' inv. − inv. '+ +B
2r 2 R
r ' R'
p' = h + + 2 inv. (r '+ R') − 2 inv. ' (r '+ R') + B
r R
29
c' c'
p' = h + + 2 c' inv. − 2 c' inv. '+ B
c c
+ 2c' inv. '−inv.
c'
B = p − 2h
c
2r ' 2r c'
B= −2 + 2c' inv. '−inv.
t 2t c
2 c'
B= r '−r + 2c' inv. '−inv.
t c
2 r'
B= r '−r + 2c' inv. '−inv.
t r
Backlash = B = 2c' inv. '−inv.
There is an infinite number of possible centre distances for a given pair of profile shifted
gears, however we consider only the particular case known as the extended centre distance.
The important reason for using non standard gears are to eliminate undercutting, to prevent
interference and to maintain a reasonable contact ratio.
The addendum of the wheel and the addendum of the pinion are generally made of equal
lengths.
Here the profile/rack cutter is advanced to a certain increment towards the gear blank and
the same quantity of increment will be withdrawn from the pinion blank.
Therefore an increased addendum for the pinion and a decreased addendum for the gear is
obtained. The amount of increase in the addendum of the pinion should be exactly equal to
the addendum of the wheel is reduced.
The effect is to move the contact region from the pinion centre towards the gear centre, thus
reducing approach length and increasing the recess length. In this method there is no change
in pressure angle and the centre distance remains standard.
30
Reduction in interference with constant contact ratio can be obtained by increasing the centre
distance. The effect of changing the centre distance is simply in increasing the pressure
angle.
In this method when the pinion is being cut, the profile cutter is withdrawn a certain amount
from the centre of the pinion so the addendum line of the cutter passes through the
interference point of pinion. The result is increase in tooth thickness and decrease in tooth
space.
Now If the pinion is meshed with the gear, it will be found that the centre distance has been
increased because of the decreased tooth space. Increased centre distance will have two
undesirable effects.
NOTE: Please refer presentation slides also for more figure, photos and exercise
problems
References:
1. Theory of Machines and Mechanisms by Joseph Edward Shigley and John
Joseph Uicker,Jr. McGraw-Hill International Editions.
2. Kinematics and Dynamics of Machines by George H.Martin. McGraw-Hill
Publications.
3. Mechanisms and Dynamics of Machinery by Hamilton H. Mabie and Fred W.
Ocvirk. John Wiley and Sons.
4. Theory of Machines by V.P.Singh. Dhanpat Rai and Co.
5. The Theory of Machines through solved problems by J.S.Rao. New age
international publishers.
6. A text book of Theory of Machines by Dr.R.K.Bansal. Laxmi Publications (P)
Ltd.
7. Internet: Many Web based e notes
31
Chapter 5: Gears Trains
A gear train is two or more gear working together by meshing their teeth and turning each other in a
system to generate power and speed. It reduces speed and increases torque. To create large gear ratio,
gears are connected together to form gear trains. They often consist of multiple gears in the train.
The most common of the gear train is the gear pair connecting parallel shafts. The teeth of this type
can be spur, helical or herringbone. The angular velocity is simply the reverse of the tooth ratio.
32
Application:
a) to connect gears where a large center distance is required
2 N T
P=
60
In an ideal gear box, the input and output powers are the same so;
2 N1 T1 2 N 2 T2
P= =
60 60
T2 N
N1 T1 = N 2 T2 = 1 = GR
T1 N2
It follows that if the speed is reduced, the torque is increased and vice versa. In a real gear box, power
is lost through friction and the power output is smaller than the power input. The efficiency is defined
as:
Power out 2 N 2 T2 60 N T
= = = 2 2
Power In 2 N1 T1 60 N1 T1
Because the torque in and out is different, a gear box has to be clamped in order to stop the case or
body rotating. A holding torque T3 must be applied to the body through the clamps.
If we use a convention that anti-clockwise is positive and clockwise is negative we can determine the
holding torque. The direction of rotation of the output shaft depends on the design of the gear box.
RA + RB = RC + RD and tA + tB = tC + tD
34
Epicyclic gear train:
Basic Theory
Observe point p and you will see that gear B also revolves once on its own axis. Any object orbiting
around a center must rotate once. Now consider that B is free to rotate on its shaft and meshes with C.
Suppose the arm is held stationary and gear C is rotated once. B spins about its own center and the
35
tC
number of revolutions it makes is the ratio . B will rotate by this number for every complete
tB
revolution of C.
tC
Now consider that C is unable to rotate and the arm A is revolved once. Gear B will revolve 1 +
tB
because of the orbit. It is this extra rotation that causes confusion. One way to get round this is to
imagine that the whole system is revolved once. Then identify the gear that is fixed and revolve it
back one revolution. Work out the revolutions of the other gears and add them up. The following
tabular method makes it easy.
Suppose gear C is fixed and the arm A makes one revolution. Determine how many revolutions the
planet gear B makes.
Step 1 is to revolve everything once about the center.
Step 2 identify that C should be fixed and rotate it backwards one revolution keeping the arm fixed as
it should only do one revolution in total. Work out the revolutions of B.
Step 3 is simply add them up and we find the total revs of C is zero and for the arm is 1.
Step Action A B C
1 Revolve all once 1 1 1
Revolve C by –1 revolution, t
2 0 + C -1
keeping the arm fixed tB
tC
3 Add 1 1+ 0
tB
t
The number of revolutions made by B is 1 + C Note that if C revolves -1, then the direction of B
tB
t
is opposite so + C .
tB
Example: A simple epicyclic gear has a fixed sun gear with 100 teeth and a planet gear with 50
teeth. If the arm is revolved once, how many times does the planet gear revolve?
Solution:
Step Action A B C
1 Revolve all once 1 1 1
Revolve C by –1 revolution, 100
2 0 + -1
keeping the arm fixed 50
3 Add 1 3 0
36
Problem 1: In an ecicyclic gear train shown in figure, the arm A is fixed to the shaft S. The wheel B
having 100 teeth rotates freely on the shaft S. The wheel F having 150 teeth driven separately. If the
arm rotates at 200 rpm and wheel F at 100 rpm in the same direction; find (a) number of teeth on the
gear C and (b) speed of wheel B.
C
100 rpm
F150
S B100
B
C Arm A
200 rpm
Solution:
TB=100; TF=150; NA=200rpm; NF=100rpm:
37
TB
Train value = −
TF
N L − N Arm N F − N A
also TV = = ( general exp ression for epicyclic gear train)
N F − N Arm N B − N A
TB N F − N A
− =
TF N B − N A
100 100 − 200
− = N E = 350
150 N B − 200
The Gear B rotates at 350 rpm in the same direction of gears F and Arm A.
Problem 2: In a compound epicyclic gear train as shown in the figure, has gears A and an annular
gears D & E free to rotate on the axis P. B and C is a compound gear rotate about axis Q. Gear A
rotates at 90 rpm CCW and gear D rotates at 450 rpm CW. Find the speed and direction of rotation of
arm F and gear E. Gears A,B and C are having 18, 45 and 21 teeth respectively. All gears having
same module and pitch.
P E
A
B
C Arm F
Q
Solution:
TA=18 ; TB=45; TC=21; NA = -90rpm; ND=450rpm:
Since the module and pitch are same for all gears :
the number of teeth on the gears is proportion al to the pitch cirlce :
rD = rA + rB + rC
T D = T A + T B + TC
T D = 18 + 45 + 21 = 84 teeth on gear D
38
Gears A and D rotates in the opposite directions:
T T
Train value = − A C
TB TD
N L − N Arm N D − N F
also TV = =
N F − N Arm N A − N F
T A TC N D − N F
− =
TB TD N A − N F
18 21 450 − N F
− =
45 84 − 90 − N F
N F = Speed of Arm = 400.9 rpm − CW
TA
Train value = −
TE
NE − NF
also TV =
NA − NF
TA N E − N F
− =
TE N A − N F
18 N − 400.9
− = E
108 − 90 − 400.9
N E = Speed of gear E = 482.72 rpm − CW
Problem 3: In an epicyclic gear of sun and planet type shown in figure 3, the pitch circle diameter of
the annular wheel A is to be nearly 216mm and module 4mm. When the annular ring is stationary, the
spider that carries three planet wheels P of equal size to make one revolution for every five revolution
of the driving spindle carrying the sun wheel.
Determine the number of teeth for all the wheels and the exact pitch circle diameter of the annular
wheel. If an input torque of 20 N-m is applied to the spindle carrying the sun wheel, determine the
fixed torque on the annular wheel.
Annular 'A'
Spider 'L'
Sun Wheel 'S'
Planet Wheel 'P'
39
Solution: Module being the same for all the meshing gears:
TA = TS + 2TP
PCD of A 216
TA = = = 54 teeth
m 4
When A is fixed:
TS
n− m=0 T A = 4 TS
TA
54
TS = = 13.5 teeth
4
But fractional teeth are not possible; therefore TS should be either 13 or 14 and TA
correspondingly 52 and 56.
40
TA − TS 56 −14
TP = = = 21teeth - This is practicable
2 4
TA = 56, TS = 14 and TP = 21
PCD of A = 56 4 = 224 mm
Also
Torque on L L = Torque on S S
5
Torque on L L = 20 = 100 N − m
1
Fixing torque on A = (TL – TS) = 100 – 20 = 80 N-m
]
D
Problem 4: The gear train shown in figure 4
is used in an indexing mechanism of a milling A C Arm
machine. The drive is from gear wheels A and B
B to the bevel gear wheel D through the gear H
train. The following table gives the number of G
teeth on each gear.
Gear A B C D E F
Number of E
72 72 60 30 28 24 F
teeth
Diametral
08 08 12 12 08 08
pitch in mm
Solution:
Gear D is external to the epicyclic train and thus C and D constitute an ordinary train.
Arm
Operation E (28) F (24) A (72) B (72) G (28) H (24)
C (60)
Arm or C is fixed 28 7 28 7
& wheel A is given 0 -1 − =− +1 -1 +1 =
+1 revolution 24 6 24 6
41
Multiply by m 7 7
(A rotates through 0 -m − m +m -m +m m
m revolution) 6 6
Add n revolutions 7 7
n n-m n− m n+m n-m n+m n+ m
to all elements 6 6
Arm A1 Arm A1
Operation S1 (24) Operation S1 (24)
P (100) P (100)
42
100 P OR A1 P
Arm P is fixed & + − 1 Arm P is fixed − − 1
P1 24 & wheel A1 is P1 S1
wheel A1 is given 0 +1 0 -1
25 given -1 A1
+1 revolution =− revolution =+
6 S1
Multiply by m 25 100 25
(A1 rotates through 0 +m − m 0 -1 =
m revolution) 6 24 6
25 Add +1 25 31
Add n revolutions
n n+ m n− m revolutions to +1 0 + 1=
to all elements 6 6 6
all elements
If A1 is fixed: n+ m; gives n = - m
NP n 1 6
= = =
N S1 n + 256 n 316 31
6
NP = N S1
31
A1 A2 S1 (24), S2 (40)
Operation Arm P
(100) (120) and Q
6
A1 is fixed & +
120 P
− 2 − 3
P2 40 31
wheel A2 is given 0 +1
18
+1 revolution =−3 =−
31
Multiply by m 18
(A1 rotates through 0 +m − 3m − m
31
m revolution)
Add n revolutions 18
n n+ m n − 3m n− m
to all elements 31
18
When P makes 1000 rpm: n− m = 1000 (1)
31
and A2 makes – 500 rpm: n+ m = -500 (2)
18
from (1) and (2): − 500 − m − m = 1000
31
(31 1000) + (500 31) = − 49 m
m = − 949 rpm
and n = 949 − 500 = 449 rpm
43
NQ = n – 3 m = 449 – (3 -949) = 3296 rpm
Problem 6. An internal
C
wheel B with 80 teeth is
keyed to a shaft F. A fixed Arm
B C
internal wheel C with 82
E
teeth is concentric with B. A E D D B
Compound gears D-E
F A
meshed with the two
internal wheels. D has 28 A
teeth and meshes with
internal gear C while E B80
meshes with B. The C82
D28
compound wheels revolve N A =800rpm
freely on pin which projects
from a arm keyed to a shaft
A co-axial with F. if the
wheels have the same pitch
and the shaft A makes 800
rpm, what is the speed of the
shaft F? Sketch the
arrangement.
rC − rD = rB − rE
tC − t D = t B − t E
82 − 28 = 80 − t E
t E = 26
− number of teeth on gear E
n = 800rpm
40 14
m+n =0
13 41
40 14
m + 800 = 0
13 41
m = −761.42rpm
Speed of gear B = m + n = − 761.42 + 800 = 38.58rpm
Speed of gear B = Speed of shaft F = 38.58rpm
Problem 7: The fig shows an Epicyclic gear train. Wheel E is fixed and wheels C and D are
integrally cast and mounted on the same pin. If arm A makes one revolution per sec (Counter
clockwise) determine the speed and direction of rotation of the wheels B and F.
Arm
B20 D15
E20 F30
C35
Solution:
Compound Gear
Operation Arm B (20) wheel E (20) F (30)
D (15) C (35)
Arm is fixed & 4 35
20 20 − − 7 20
B is given
ONE
0 +1 − − 3 20 −
15 15 7 3 30 45
revolution
=+
(CW) 3
Multiply by m
Since the wheel E is fixed and the arm A makes 1 rps-CCW
7
n = −1rps and m+n =0
3
7 3
m −1 = 0 m = = 0.429
3 7
Speed of gear B = m + n = 0.429 − 1 = −0.571rps (CCW )
14 14
Speed of gear F = n − m = −1 − 0.429 = −1.667 (CCW )
9 9
Problem 7: In the gear train shown, the wheel C is fixed, the gear B, is keyed to the input shaft and
the gear F is keyed to the output shaft.
D60
Output
Shaft A E30
Input
Shaft
B20
F32
C80
The arm A, carrying the compound wheels D and E turns freely on the out put shaft. If the input
speed is 1000 rpm (ccw) when seen from the right, determine the speed of the output shaft. The
46
number of teeth on each gear is indicated in the figures. Find the output torque to keep the wheel C
fixed if the input power is 7.5 kW.
Solution:
Data :
tB = 20; tC = 80; tD = 60; tE = 30; tF = 32; NB = 1000 rpm (ccw) (input speed); P = 7.5 kW
Compound Gear
B (20) wheel
Operation Arm C (80) F (32)
Input
D (60) E (30)
1 60 1 30
20 1 1 − −
Arm is fixed &
B is given +1
0 +1 = 3 80 3 32
60 3 3 1 5
revolution
=− −
4 16
Multiply by m
1 1 1 5
(B rotates
0 m m m − m − m
through m
3 3 4 16
revolution)
Add n 1 1 1 5
revolutions to n m+n m+n m+n n− m n− m
all elements 3 3 4 16
Input shaft speed = 1000 rpm (ccw)
i.e., gear B rotates – 1000 rpm
m + n = −1000
1
Gear C is fixed ; n− m = 0
4
− 1000 − m − 0.25m = 0
1000
m=− = −800
1.25
n = − 1000 + 800 = − 200
5
Speed of F = n − m
16
5
= − 200 + 800
= 50
16
Speed of the output shaft F = +50rpm (CW )
47
2 N BTB
Input power = P =
60
2 −1000 TB
7.5 1000 =
60
7500 60
TB = − = −71.59 Nm
2 1000
From the energy equation;
TB N B + TF N F + TC N C = 0
Since C is fixed : N C = 0
TB N B + TF N F = 0
− 71.59 1000 + TF 50 = 0
TF = +1431.8 Nm
From the torque equation :
TB + TF + TC = 0
− 71.59 + 1431.8 + TC = 0
TC = −1360.21Nm
The Torque required to hold the wheel C = 1360.21 Nm in the same direction of wheel
A2 A1
Operation
(100) (120)
S1 (40) Figure 6
48
A2 is fixed & 120
wheel A1 is given 0 +1 − =−3
+1 revolution 40
Multiply by m
(A1 rotates through 0 +m − 3m
m revolution)
Add n revolutions n − 3m
n n+ m
to all elements
A1 is fixed: m = −n
N S1 n + 3n
= =4
N A2 n
N S1 = 4 N A2
(b) Consider complete gear train:
S2 is fixed m=-n
6
n+ n
N S1 5 = 11 10 = 22
=
N A2 3 5 13 13
n+ n
10
Input torque on S1 = TS1 = 300 N-m, in the direction of rotation.
TA 2
Resisting torque on A2;
22
T A 2 = 300 = 507.7 N − m
13
A2
→ opposite to directiojn of rotation TS 2
49