DESIGN OF PLANETARY GEAR TRAIN

We choose the following parameters for sun gear:

Module, m= 1.375 mm

Pressure angle = 20

Number of teeth, Zs =36

Number of teeth of planet gear = 19

Number of teeth of ring gear = 73

For epicyclic gear train following criteria should be satisfied:

m (Zp +2) < m(Zp + Zs) ( sinπ/n)

Where,

n is Number of planet gear = 4

Number of teeth on sun gear = Zs

Number of teeth on planet gear = Zp

Number of teeth on ring gear = Zr

Therefore, L.H.S: 1.375(19+2) = 28.8

R.H.S: 1.375(19+36) sin (π/4) = 75.6

L.H.S < R.H.S

Hence, above criteria is satisfied.

Zr = 73

According to i = 1+ Zr/Zs

i = 1 + 73/36

i = 3.02

Reduction is 3

Design of sun gear

By using above equation,

m(Module) = D/Z

D = m*Z

Pitch Circle Diameter of sun gear (Ds): 1.375*36 = 49.5 mm

Pitch of sun gear = π*D/T

= 3.14*49.5/36

= 4.32 mm

Addendum = Module + Module * (1 / cos(pressure angle))

= 1.375 mm + 1.375 mm * (1 / cos(20°))

≈ 2.84 mm
Addendum circle Dia = Pitch circle Dia + Addendum

= 49.5 + 2.84

= 52.34 mm

Dedendum = Module = 1.375 mm

Dedendum Circle Dia = Pitch circle Dia – Dedendum

= 49.5 – 1.375

= 48.125 mm

Convert the pressure angle to radians:

φ = 20° * (π / 180°) ≈ 0.349 radians

Calculate the base circle radius:

R = D / 2 * cos(φ)

R = 49.5 mm / 2 * cos(0.349) R ≈23.255mm

Diameter of Base Circle Radius = 2*R

= 2*23.255

=46.51 mm

• Clearance (c): The clearance is a small gap between the teeth of mating gears to prevent them from binding.
It's typically a fraction of the module. A common value is 0.25 * module.

Clearance = 0.25 * Module = 0.25 * 1.375 mm = 0.34 mm

• Tooth thickness (t): The tooth thickness is the width of a tooth measured along the pitch circle. It can be
calculated using the formula:

Tooth thickness = Circular pitch - Clearance = 4.32 mm - 0.34 mm = 3.98 mm

• Whole depth (h'): The whole depth is the total depth of a tooth, from the tip to the root.

Whole depth = Dedendum + Addendum = 1.375 mm + 2.84 mm = 4.21 mm

• Working depth (hw): The working depth is the depth of a tooth that engages with another gear. It's equal to
the whole depth minus the clearance.

Working depth = Whole depth - Clearance = 4.21 mm - 0.34 mm = 3.87 mm

• Fillet radius (r): The fillet radius is a small curvature at the base of the tooth to improve strength and reduce
stress concentration. It's typically a fraction of the module. A common value is 0.5 * module.

Fillet radius = 0.5 * Module = 0.5 * 1.375 mm = 0.69 mm

Design of Planet gear

Pitch Circle Diameter of planet gear (Dp): 1.375*19 = 26.125 mm

Addendum = Module + Module * (1 / cos(pressure angle))

= 1.375 mm + 1.375 mm * (1 / cos(20°))

≈ 2.84 mm

Addendum circle Dia = Pitch circle Dia + Addendum

= 26.1 + 2.84

= 28.94 mm

Dedendum = Module = 1.375 mm

Dedendum Circle Dia = Pitch circle Dia – Dedendum

= 26.1 – 1.375

= 24.725 mm

Convert the pressure angle to radians:

φ = 20° * (π / 180°) ≈ 0.349 radians

Calculate the base circle radius:

R = d / 2 * cos(φ_rad) = 26.12 mm / 2 * cos(0.349 rad) ≈ 13.06 mm

Base Circle Radius = 13.06*2 = 26.12 mm

Design of Ring gear

Pitch Circle Diameter of ring gear (Dr) : 1.375*73 = 100.37 mm

Addendum = Module + Module * (1 / cos(pressure angle))

= 1.375 mm + 1.375 mm * (1 / cos(20°))

≈ 2.84 mm

Addendum circle Dia = Pitch circle Dia + Addendum

= 100.375 + 2.84

= 103.215 mm

Dedendum = Module = 1.375 mm

Dedendum Circle Dia = Pitch circle Dia – Dedendum

= 100.37 – 1.375

= 98.995 mm

Convert the pressure angle to radians:

φ = 20° * (π / 180°) ≈ 0.349 radians

Base circle diameter (Db) = Module (m) * Number of teeth (N) / Cos(Pressure angle (α))

Calculate the result:

Db ≈ 27.80 mm (rounded to two decimal places)

The inner diameter (Di) can be calculated by subtracting twice the addendum and the clearance from the pitch circle
diameter:

Di = Dp - 2 * ha - c ≈ 95.295 mm
Calculating Planetary Gear Speeds

Maximum Rpm given by motor = 8000 rpm

• Sun gear speed (Sun_RPM) = 8000 rpm

• Number of planet gears (N) = 4

• Planet teeth (P) = 19

• Ring gear teeth (R) = 73

• Planet gear acts as the output (carrier is stationary)

• Output gear ratio (G) = 3 (planet carrier speed relative to sun gear)

Planetary gear sets have two main configurations:

1. Sun gear as input, carrier held stationary: In this case, the formula for planet gear speed (Planet_RPM) is:

Planet_RPM = (Sun_RPM * R) / (R + 2 * P)

2. Planet carrier as input, sun gear held stationary: This is your scenario, where the planet gear acts as the
output, and the carrier is fixed. In this configuration, the planet gear speed is the same as the carrier speed
(Planet_RPM = Carrier_RPM).

Since the carrier is held stationary, the planet gear speed (Planet_RPM) becomes:

Planet_RPM (Carrier_RPM) = Sun_RPM / G

where G is the output gear ratio (planet carrier speed relative to sun gear).

Plugging in the values:

• Planet_RPM (Carrier_RPM) = 8000 rpm / 3

• Planet_RPM (Carrier_RPM) = 2666.67 rpm (rounded to two decimal places)

Therefore, the planet gear (acting as output) and the carrier will rotate at approximately 2666.67 rpm.

Ring Gear Speed:

With the carrier held stationary, the ring gear will rotate in the opposite direction to the planet gears. The speed of
the ring gear (Ring_RPM) can be calculated using another formula:

Ring_RPM = - (Sun_RPM * (R - P)) / (R + 2 * P)

• The negative sign indicates the opposite direction of rotation.

Ring_RPM = - (8000 rpm * (73 - 19)) / (73 + 2 * 19)

• Ring_RPM ≈ -3333.33 rpm (rounded to two decimal places)

Therefore, the ring gear will rotate in the opposite direction at approximately 3333.33 rpm.