Figure 26:

5 Worm and wheel gear

These gears are usually used with non-intersecting shafts which are usually at shaft angle
90o
The worm is the member having screw like threads which may be single or multi-start.
The teeth of the gear wheel are inclined to the axis at the lead angle of the screw. The
teeth of the wheel are concave so as to give line contact.
The lead of the worm which is the axial advance of the thread per revolution. This is
equal to the length between pitch of the same threads.

lead = np

Where, n=Number of threads and p=Pitch

Lead angle of the worm γ corresponds to the helix angle of the wheel and is given by.

L
tan γ =
πd
Where, L=lead and d=mean worm diameter. Let ω=angular velocity of the worm and
Ω=angular velocity of the wheel.
Then
ω No. of teeth on wheel
=
Ω No. of threads on worm

NB: It’s very hard to turn the worm by turning the wheel. The practice is to turn the
wheel by turning the worm

6 Gear train

A gear train is a system consisting of two or more meshing gears, designed to provide
a desired angular speed ratio between the shaft of the input gear and that of the out-
put gear. There are four basic types of gear trains: simple, compound, reverted, and
planetary (or epicyclic).

31
1. A simple gear train is one in which each shaft carries only one gear, as shown
in Figure 27(a). In this type of train, the centerlines of all shafts or axles are
fixed relative to the housing or frame, and all gears have the same diametral pitch.
Simple gear trains are used in applications where the speed ratio is comparatively
low.

2. A compound gear train is one in which one or more shafts carry more than one
gear, as shown in Figure 27(b). Like the simple gear train, the shafts or axles are
also fixed relative to a frame. However, the diametral pitch may or may not vary
from stage to stage. Compound gear trains are used in applications where large
speed ratios are desired.
The advantages of compound train includes

(a) A large speed ratio may be obtained with wheels of smaller diameters.
(b) The drive may be transmitted round bends or corners and even returned upon
itself so that driving and driven shafts are coaxial.

3. A reverted gear train is a compound gear train in which both input and output
gears rotate about coaxial shafts, as shown in Figure 27(c). One of the most
important advantages of this type of train is its compactness. Some common
applications of the reverted gear train include automatic transmissions, industrial
speed reducers, and clocks.

4. A planetary (or epicyclic) gear train is one in which one or more gears rotate
about a moving axis as shown in Figure 27(d). Usually, this type of gear train
consists of four elements: a central gear, the sun gear; a meshing pinion, the planet
gear; a connecting arm, the planet arm; and an internal gear, the ring gear, inside
of which the planet gear rotates.

Special aspect of epicyclic gear train

(a) The input and output shafts lie on a common axis and therefore the train is
compact.
(b) Loads can be spread in the number of parallel gears and therefore high torque
can be achieved.
(c) Static and dynamic forces are balanced if multiple planets are used.
(d) High reductions are possible within very compact arrangement by connecting
2 or more planetary trains in series.
(e) In variable gear boxes such as in car, the gear can remain in mesh all the
times, while brakes are applied to various elements in turn to obtain the
ration required. This reduces wear on the gears.

32
 (a) Simple gear train (b) Compound gear train

(c) Reverted gear train (d) Planetary gear train

Figure 27:

6.1 Simple gear train

Let Na , Nb , Nc . . . be the rotational speeds of A, B and C . . .. Let Ta , Tb . . . be the

number of teeth in A, B. . ., then the velocity ratios
Na Tb
=
Nb Ta
Nb Tc
=
Nc Tb
Nc Td
=
Nd Tc

33
 A

Figure 28:

Then,
Na Na N b N c
= . .
Nd Nb Nc Nd
Tb Tc Td
= . .
Ta Tb Tc
Na Td
=
Nd Ta

Hence the ratio of speeds A and D depends on the number of teeth of the two wheels A
and D. The intermediate wheels has no effect on V.R given by the train. However, they
can affect the sense of rotation of D for a given sense of rotation of A. When the number
of intermediate wheels is even the sense of rotation of driver is opposite that of driven.
On the other hand if the number is odd the sense of rotation of driver is the same as
that of driven. Note that this rule can not be applied where shafts intersects such as in
the case of bevel gears.
Intermediate wheels serves to break the gap between the first and the last wheel. They
are also some times used to drive auxiliary incidental to the main train.

6.2 Compound gear train

When each shaft except the first and last carries two or more wheels, the gear train is
referred to as compound train.

34
 Driver

A A
Input
Driver

B B
C C

D Output
Follower D

Follower

Figure 29:

NA TB NC TD
= =
NB TA ND TC

But

N B = NC

NA NA N B NA NC
= . = .
ND NB ND N B ND
TB .TD
=
TA .TC

Thus

Speed of driver Product of teeth on follower

=
Speed of follower Product of teeth on driver

NA TB NC TD NE TF
= , = , =
NB TA ND TC NF TE

But

NC = NB , NE = ND

Therefore

NA NA N C N E TB .TD .TF
= . . =
NF NB ND NF TA .TC .TE

35
 A

B C

F
E

Figure 30:

6.3 Reverted gear train

In a reverted train the equation R1 + R2 = R3 + R4 must be satisfied where R s are

radius of gears

R4
R1

distance
Center
R3
R2

Figure 31:

m 1 R1 m 2 R2 m 3 R3 m 4 R4
+ = +
T1 T2 T3 T4
The teeth numbers that satisfy the equations for gear ratio and center distances are
usually found by trail method
N1 TFollower T2 .T4
= =
N4 TDriver T1 .T3

Example

Two parallel shafts x and y are connected by toothed wheels, wheels A and B form a
compound pair which can slide along but rotate with shaft x. Wheels C and D are
rigidly attached to shaft y and compound pair may be moved so that A engages with

36
C or B engages with D. Shaft x rotates at 640 rpm and speeds of y are to be 340 rpm
exactly and 240 rpm as nearly as possible.Using a module of 12 for all wheels.

(a) Find the minimum distant between shaft axes.

(b) Suitable teeth for the wheels

(c) Speed of shaft y

Example

Two shafts A and B in the same straight line are geared together through an intermediate
parallel shaft C. The wheels connecting A and C have module of 2 and those connecting
C and B have modules of 3.5. The speeds of B is to be about 0.1 that of A. If the
2 pinions have each 24 teeth. Find suitable number of teeth for the wheels, the actual
ratio and the corresponding distance of shaft C from A.

6.4 Planetary gear train

An epicyclic gear train is also called planetary or sun and planet gear train. Consider a
simple epicyclic gear train.

L
S

Figure 32:

A is the annulus, having internal gears. S is the sun gear, P is the planet gear, L is
the arm. For balancing the number of planet gears may be increased, but adding more
planet gear contribute nothing to kinematic performance. A major application of the
said gears is in automobile differential.
A point on planet gear follows an epicycloidal path hence the name epicyclic gear. For
the differential unit the ring gear acts as planet carrier and its speed can be calculated
as for a single gear train when speed of drive shaft is known. When a car is traveling in a
straight line the two gear rotates in the same direction with exactly the same speed. In
this case there no relative motion between motion between the planet gears and the sun
gears. The planet gear in effect serves only as key to transmit motion from the planet

37
carrier to both wheels. During turning the planet gears rotates about their own axes
thus permitting the sun gears to revolve at different velocity.

6.4.1 Determination of velocity ratio in simple epicyclic train-The superpo-

sition method

Consider a simple epicyclic train

L A
S

Figure 33:

NB: The annulus, arm or sun wheel may be fixed and do not need to be disengaged in
order to obtain different V.R support we need to find V.R of S to L when A is fixed.

Step 1
Rotate each member through one complete revolution clockwise.

Step 2
Hold the arm fixed and rotate the annulus through 1 revolution anticlockwise thus re-
turning to the former position of the annular. Since L is fixed the revolutions of P and S
due to rotation of A are −T
TP
A
and +TTS
A
respectively. Further we deduct a zero revolution
of L

Step 2
Add the corresponding rotation in each member in step 1 and 2 to obtain the resultant
motion. This gives the relative motion of the arm, sun wheel and planet wheel when the
annulus is fixed.
L A P S
(1) Turn whole gear clockwise 1rev +1 +1 +1 +1

−TA TA
(2) Hold L, turn the fixed wheel anticlockwise 1rev 0 -1 TP TS
+

(3) Add (1) and (2) 1 0 1 − TTPA 1+ TTAS

38
Therefore,
NL 1 NL 1 NP 1− TA
TP
= , = , =
NP 1 − TTPA NS 1 + TTAS NS 1+ TA
TS

When all members are rotating the whole member is given +a revolution then the arm
held fixed and any wheel is given +b revolution. The motion of other wheels is found in
the same way as above. The resulting motion found by adding (1) and (2) is in terms of
a and b which are then evaluated from the known speeds of the two members.
L A P S
(1) Turn whole gear clockwise 1rev +a +a +a +a

+TA .b −TA .b
(2) Hold L, turn the fixed wheel anticlockwise 1rev 0 +b TP TS

(3) Add (1) and (2) a a+b a+ TTAP.b a− TTAS.b

6.4.2 Compound epicyclic gear train

This a combination of 2 or more simple epicyclic gear trains.

A2
A1
P2
P1

Input L
S2
S1
Output

Figure 34:

The annulus A1 of the train A1 S1 L also form the arm of the train A2 S2 A1 . Let A2 be
fixed first obtain the ratio of L to S1 when A1 is fixed.
L A1 S1
(1) Give whole train +1rev +1 +1 +1

T A1
(2) Hold L, give A1 -1rev 0 -1 TS1

T A1
(3) Add (1) and (2) +1 0 1+ TS1
 
NL 1
Therefore, N
when A1 is fixed= TA
1
.
1+ T
S1
Next the whole train with A1 as the fixed arm.

39
 L1 A1 S1 S 2 A2
(1) Give whole train 1rev +1 +1 +1 +1
 
TA2 /TS2 +TA2
(2) Hold A1 and give A2 -1rev TA
1
0 TS2
-1
1+ T
S1

 
TA2 /TS2 T A2
(3) Add (1) and (2) 1+ TA
1
1 1+ TS2
0
1+ T
S1

 TA

2
TS
2
1+ TA
1
NL 1+ T NL
Thus, =  S1
 =
NS1 1+
T A2 NS2
TS2

NS1 TA NA 1 TA
= 1, = 1
NA 1 T S1 NS 1 T S1

Example

The figure shows epicyclic gear train for a compressor with input shaft R and output
shaft Q, the arm L carry a pin on which compound planet wheels P1 and P2 are free
to rotate. The wheels have the following number of teeth Ts =60, TP1 =28, TP2 =22 and
TA =110. Find the output speed of shaft Q given that the input speed is NR =500 rpm.

Solution

P
 1 , P2 S,
 R  L, Q A
TA −TP2 TA
(1) Hold Arm L and give A +a revs TP1
a .
TS TP1
a 0 a

(2) Lock all gears and give a whole train b b b b

+b rev
   
TP2 TA .a
(3) Add (1) and (2) b+ TA
TP1
a b− .
TS TP 1
b a+b

NR =500 rpm.
TP2 .TA
⇒b− = 500
TS .TP1

NA = 0 ⇒ a + b = 0

From which a = −204.88, b = 204.88. Therefore NQ =204.9 rpm

40
6.5 Torque on gear trains

Let
ci =Applied input torque
co =Resisting torque on output shaft
ch =Torque to hold the casting fixed

Output shaft

Casting
Input shaft

Figure 35:

If there is no acceleration of the system the net torque applied to the unit about any
axis must be zero. Also kinetic energy of the system remains constant so that the net
work done per second is zero.

ci + co + ch = 0

ci ωi + co ωo = 0

It is important to assign the appropriate signs to the torques and velocities in these two
equations. If the casting is not fixed cn represent either input or output torque

Case 1: Input and output shafts rotating in the same direction.

In this case the direction of holding torque will depend on relative magnitude of Ci and co

Case 2: Input and output shafts rotating in opposite direction

In this case the direction of holding torque is opposite that of input torque. If there is
friction the efficiency of the unit η is given by
Power output co ωo
η= =
Power input ci ωi

ηci ωi + co ωo = 0

41
 cn co
o
Output shaft
cn

i

ci
Input shaft

Figure 36:

o

cn
co

ci
i

Figure 37:

6.6 Acceleration of gear train

ωB
If any two shafts A and B are rotating in fixed gear ratio G = ωA
, then the accelerations
will also be at the same ratios
αB
=G
αA

Let IA be the moment of inertia of A and IB be the moment of inertia of B. The the
torque to accelerate A is equal to IA αA . Torque to accelerate B is equal to IB αB . Power
required to accelerate the system

P = Tω

= (IA αn )ωA + (IB αB )ωB

But ωB = GωA and αB = GαA .

42
 A

A

B B

Figure 38:

⇒ P = In αA ωA + (IBG αA )GωA

= (IA + G2 IB )αA ωA

This power is produced by applying torque TA to A

Then power=TA ωA

⇒ TA ωA = (IA + G2 IB )αA ωA
= (IA + G2 IB )αA
TA = Ie αA

Ie is the equivalent inertia of the system referred to A

Consider a simple train as shown in the figure. 39
Let S be the driving wheel and L be the driven shaft. Total kinetic Energy of the system

1 1 1 1
K.E = IS ωS2 + IL ωL2 + 3( IP ωP2 + mP vP2 )
2 2 2 2
ωS2   ω 2
L
  ω 2
P
 ω × v 2 
L
= IS + IL + 3 IP + mP
2 ωS ωS ωs

Energy supplied to the system in unit time is equal to gωs

43
 P

L A
S

Figure 39:

44