Introduction of Gears

Gears are among the most important power transmission elements. A gear is a rotating machine
element having cut teeth which mesh with another toothed part, usually having teeth of similar
size and shape, in order to transmit power. Two or more gears working together are called a
“transmission” (or gear set) and can produce “mechanical advantage” and thus may be
considered a simple machine. The mechanical advantage is a measure of the force or torque
amplification that is obtained using mechanical devices. When two gears mesh with one gear
bigger than the other (the size of the teeth must match thus the bigger gear has more teeth), a
mechanical advantage is obtained where the rotational speeds and the torques of the two gears
will be different. Since the input and output power must be equal (ignoring friction losses), there
is an inverse relationship between the speed and torque ratios (the small gear will have higher
speed and lower torque and the larger gear will have lower speed and higher torque). A
transmission (or gear set) can be used to change the speed, torque, direction of rotation, direction
of a power source, or the type of motion. The most common configuration for a gear is to mesh
with another gear, however, a gear can also mesh with a non-rotating toothed part, called a
“rack”, thereby producing translation instead of rotation, as shown in the figure. Such
arrangement is refered to as “rack and pinion” and it is commonly used in the steering systems of
automobiles.

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Types of Gears

There are four principal types of gears:

 Spur gears: The simplest type of gears. The teeth are parallel to the axis of rotation, as seen
in the figure. It transmits rotation between parallel shafts.

 Helical gears: The teeth are inclined with respect to the axis of rotation, as seen in the figure.
Same as spur gears, it transmits rotation between parallel shafts, but it is less noisy than spur
gears because of the more gradual engagement of the teeth during meshing and thus it is
more suitable for transmitting motion at higher speeds. In some cases, helical gears can also
be used to transmit rotation between perpendicular shafts, as seen in the figure.

 Bevel gears: The teeth are somehow similar to those of a spur gear but they are formed on
conical surfaces instead of cylinders. Bevel gears transmit rotation between intersecting
shafts. The gear shown in the figure has straight teeth where this is the simplest type.
However, there are other types were the teeth form circular arcs and it is called spiral bevel
gears, as shown in the figure. With spiral bevel gears, the teeth engagement will be more
gradual (similar to helical gears) and thus it is less noisy and it is suitable for higher speeds.

 Worms and worm gears: Transmit rotation between perpendicular shafts (not intersecting,
there is an offset between them). The worm resembles a screw which can be right handed or
left handed. Worm gear sets are usually used when high reduction in speed is desired (speed
ratios of 3 or higher). It transmits rotation from the worm to the worm gear, but not the
opposite.

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GEAR MANUFACTURING METHODS:

1] CASTING: -
It is the cheapest method producing the gear whereeconomy is the main criteria. This method of
producing gears is thesame as that used for casting other products. Usually heavy gears aremade
by this process. They are not efficient in transmitting power. Theyare generally used for slow
speed drive. Cast iron gears are made by thismethod comfortably.

2] STAMPING: -
This process is widely used for mass production ofsmall and their gears. This method is used for
metal sheets upto athickness of 3 mm. It is high accuracy and surface finish. Gears used intoys,
watches, clocks etc. are produce by this method.

3] ROLLING: -
Both hot and cold rolling process are used to makegears. In hot rolling, gear blank is rolled
against a master gear (hardenedsteel gear) to produce desired teeth on its periphery. The cold
rolling process is similar to hot rolling but requires high pressure.

4] POWDER METALLURGY: -
Small size high quality external orinternal spur, bevel or spiral gears are also produced by
powdermetallurgy process. Large size gears are rolled after briquetting andsintering for more
strength and life. Powder metallurgically producedgears hardly require any further finishing
work.

5] EXTRUSION: -
It is well suitable for production of small size gears from material like AC, brass and bronze. In
this process are heated gear blank is placed inside the cylinder and pressed from one end with a
ram.The other end carries a die similar to the shape of the required gear. Themethod is used for
mass production

6] PLASTIC MOULDING:
- In plastic moulding, gears of plasticmaterial can be manufactured by using injection moulding
orcompression moulding. These are the very light duties gears used fortransmission of very low
amount of power but maintains velocity ratioaccurately. Non-ferrous metal can also be used as
raw material for gearmaking by plastic moulding methods

7] MACHINING: -
This is most widely used method for manufacturingof gear. It is also the most accurate method of
gear manufacturing. Gearis prepared by cutting one-by-one tooth in the gear blank of
desiredshape and size along its periphery. In this method the metal is removedin the form of
chips.

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SELECTION OF GEAR MANUFACTURING METHOD: -

Type of gear

Size of gear

Quantity required

Accuracy desired

Cost and availability of equipment

GEAR MANUFACTURING BY MACHINING GENERATINGMETHOD: -

1]
GEAR SHAPING: -
Gear Shaping is a machinery process thatinvolves continuous, same-plane rotational cutting
.
It is an accuratecutting process that produces a high surface finish on both external andinternal
teeth. Shaping can generate many gear types including spurs,involute
splines, helical, herringbones, and racks

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2]

GEAR HOBBING: -Hobbing is a machining process for gear cutting,cutting splines, and cutting
sprockets on a hobbing machine, which is aspecial type of milling machine. The teeth or splines
of the gear are progressively cut into the material (a flat, cylindrical piece of metal) bya series of
cuts made by a cutting tool called a hob. Compared to othergear forming processes it is relatively
inexpensive but still quiteaccurate, thus it is used for a broad range of parts and quantities.

3]

BEVEL GEAR GENERATION: -These gears have modified teeth.Bevel gears are used in
situations in which it is important to invert thedirection of rotation of the shafts. In spiral bevel
gears, the teeth arecurved in order to provide for a smoother meshing and greater tooth vs.tooth
contact when compared to a straight bevel gear.

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4]

GEAR GRINDING: -Gear grinding is the name of a specificgear creation technique

Grinding involves the removal ofunwanted materials through an abrasion process. Grinding
istypically the last step in the gear creation process; other techniqueshave removed the majority
of the material first. There are severalmethods of grinding, but not all of them a used
for the ofgears

GEAR LAPPING: -Gear lapping is the process of imparting avery fine finish and high degree of
accuracy to gear teeth by usinga lapping tool and applying a fine-grained abrasive between
awork material and a closely fitting surface, called a lapping plate

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NEED OF GEAR FINISHING: -
i.

For smooth running, good performance and long service life, thegears need
ii.

To achieve be accurate in dimensions and forms.

iii.

To achieve high surface finish.

iv.

To be hard and wear resistive at their tooth flanks.

v.

To remove inaccuracies produced through gear generating process.APPLICATION1)

Automobile2)

Industrial industries3)

To transfer a motion from one shaft to another shaft4)

It also used to transmit a power from one shaft to anot

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REFERANCE
•

NIRALI PRAKASHAN
•

SLIDESHARE
•

WEKIPEDIA

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