UNIT 4 -GEAR BOX

AT6602 -AUTOMOTIVE CHASSIS

COMPONENTS DESIGN
GEAR BOX DEFINITION
Gear box which contains a number of gears
arranged in a specific format and by changing
the positions of some gears with respect to
other gears, many speeds can be received.
Another important applications of gear box is
in automobiles where low speed is required at
starting and stopping and high speed during
running.
 FUNCTION OF GEAR BOX
A gear box is containing many gears of different
numbers of teeth, arranged in different shafts which
may be solid shafts or splined shafts.
In the solid shafts, the gears are fitted in such a way
that they can rotate only and cannot move in the axial
directions and also some gap is provided in between
two gears.
whereas in splined shafts two or three gears, which
are already meshed together to act as a single unit, are
fitted in such a way that they can rotate and also
move in the axial directions.
 Gear Trains
Introduction:
Sometimes, two or more gears are made to mesh with
each other to transmit power from one shaft to another.
Such a combination is called gear train or train of
toothed wheels. The nature of the train used depends
upon the velocity ratio required and the relative
position of the axes of shafts. A gear train may consist
of spur, bevel or spiral gears.
 Types of Gear Trains:
1. Simple gear train,
2. Compound gear train,
3. Reverted gear train, and
4. Epicyclic gear train.
In the first three types of gear trains, the axes
of the shafts over which the gears are mounted
are fixed relative to each other.
But in case of epicyclic gear trains, the axes
of the shafts on which the gears are mounted
may move relative to a fixed axis.
Simple Gear Train
Compound Gear Train:
Let N1 = Speed of driving gear 1,
T = Number of teeth on driving gear 1,
1
N2 ,N3 ..., N6 = Speed of respective gears in r.p.m., and
T ,T ..., T = Number of teeth on respective gears.
2 3 6
Since gear 1 is in mesh with gear 2, therefore its speed
ratio is
…………(i)
Similarly, for gears 3 and 4, speed ratio is
………(ii)
and for gears 5 and 6, speed ratio is
…………(iii)
1.The gearing of a machine tool is shown in Fig. 13.3.
The motor shaft is connected to gear A and rotates at
975 r.p.m. The gear wheels B, C, D and E are fixed to
parallel shafts rotating together. The final gear F is
fixed on the output shaft. What is the speed of gear F?
The numbers of teeth on each gear are as given below:
Reverted Gear Train:
Since the distance between the centers of the shafts of
gears 1 and 2 as well as gears 3 and 4 is same, therefore
r + r= r+ r...(i) 1 2 3 4
Also, thecircular pitch or module of all thegears
is assumed to be same, therefore number of teeth on
each
gear is directly proportional to its circumference
or radius.
Epicyclic gear
train:
2. The speed ratio of the reverted gear
train, as shown in Fig. 13.5, is to be 12.
The module pitch of gears A and B is
3.125 mm and of gears C and D is 2.5 mm.
Calculate the suitable numbers of teeth for
the gears. No gear is to have less than 24
teeth.
Solution:
Given:
Speed ratio, NA/ND = 12; mA = mB =3.125 mm;
m = m =2.5 mm
C D
3.125 (TA + TB) = 2.5 C + TD) =
∵ mA = mB, and400
...((T m C = mD )
(TA + TB) = 400 / 3.125 = 128 ...
(ii)
and (TC + TD) = 400 / 2.5 = 160 ...
(iii) (i), TB = 3.464 TA. Sub.
From equation
this value of TB in equation
(ii),
TA + 3.464 TA = 128 or A = 128 / 4.464
T 28.67 say 28 Ans.
=
and TB = 128 – 28 = 100 Ans.
Again from equation (i), TD = 3.464 TC.
Substituting this value of TD in equation
(iii), TC + 3.464 TC = 160 or TC = 160 /
4.464 = 35.84 say 36 Ans.
and TD = 160 – 36 = 124 Ans.
Bearings
 Bearings
Function:
• Carry load in one or several directions while
allowing frictionless motion in other directions

Fatigue = F(Pressure, Velocity)

• 3 main types of Bearings

– Rolling Element Bearings
– Sliding Bearings
– Elastomeric Bearings
 2 TYPES OF ROLLING
BEARINGS

I. Ball Bearings

II. Roller Bearings

 I. Ball Bearing: Outer
race

• Ball Bearing
– Incorporates hardened
steel balls
– Steel balls geometrically
contact inner and outer
race at a point
– This creates high stresses
locally

seals Inner race

cage
 Ball Bearings

How to Assemble
-Inner race press fit onto
shaft shoulder (FN1, FN2)
-Assembly slides into
housing (RC2) between outer
race and housing
 Types of Ball Bearings
• Deep Groove Ball
Bearings
– Primarily radial load
carrying
– Thrust load equal to
25% of radial load
– Can get as large as
300K radial load
capacity
 Types of Ball Bearings

• Double Deep Groove

– Increases radial load
 Types of Ball Bearings
• Angular contact ball bearing
– Increased thrust load due to increase in
lateral contact area between ball and race
 Types of Ball Bearings

• Thrust Bearings
– Used in applications
with significant thrust
load
Types of Ball Bearings
• Super precision ball
bearings
– Nearly perfect
spheres
– High surface finish
• Applications
– High speed grinding,
milling, boring, routing
– No Vibration!!
• Ceramics
– Hard
– No deformation
 II. Roller Bearings

• Roller Bearings
– Hardened steel cylindrical rollers
– Line contact deforms into areas larger then
ball bearings
– Capable of carrying higher radial loads
 Types of Roller Bearings

• Needle Bearings
– 4 joint machine
applications
– As the number of rollers
goes up the greater the
contact area
– The greater the contact
area the greater the load
 Types of Roller Bearings

• Spherical Roller Bearings

– Centers inner race about
shaft to avoid binding
 Types of Roller Bearings

• Tapered Roller Bearing

– Support high thrust
loads (wheel bearing)
– Supports radial load (car
weight) while supporting
thrust loads (cornering)
– Wheel rotates with little
resistance/friction
 Types of Roller Bearings

• Thrust Roller Bearings

– Used in applications
with significant thrust
load
Mounted Bearings

Precision machine
elements such as
transmissions, reducers,
right angle drives
usually incorporate un-
mounted bearings
 Other Types of Bearings
• Thompson linear
bearings
• Sliding Bearings
– No rolling
elements
– Sleeve over shaft
where sleeve acts like
bearing (Generally
higher friction)
– Bronze good material
due to coefficient of
friction, porosity and
wear resistance
 Other Types of Bearings
• Self Lubricating
Bearings
– Low Friction
– No lubrication
needed

Elastomeric
Bearings
Ball Joint – 3 rotational DOF

See heim overview powerpoint

 Selecting Bearings
Load-Life Relationship:

k
L  P  P1 = load 1, L1 = life at load 1,

2
  1 
L1  P2 
k = 3.00 for ball bearings
k = 3.333 for roller bearings

Example: A ball bearing lasts 3,000 hours at 500 lb,

how long will it last at 1,000 lbs? SIMPLE!
 Selecting Bearings Cont’d
k
L  P  Most manufacturers specify
basic dynamic load rating, C,
2
  1 
L1  P2  which is the load that results
in 106 cycles. So, this
equation can be rewritten as:
k

C  6 = Design Life for your

Ld    1 0 specific application for a
design load of Pd
P d 
1/ k
 Ld  = Required dynamic load

CPd  6  rating for a design life =

Ld
 10  Note, these are all L10 lives!!!
Which is the life for 90%
“2” = 200
series
Example: A horizontal washing machine rotates at 1,100 rpm. Spec out
bearings on ends if the dynamic radial load is 400 lb and static load is 75
lb. Want machine to last 20 years @ 3 loads per day, 30 minute cycle
time/load.
1. In a gear box the clutch shaft of the pinion
has 14 teeth and low gear main shaft pinion 32
teeth. The corresponding lay shaft pinions have
36 and 18 teeth. The rear axle ratio is 3.7 : 1
and the effective radius of the rear tyre is 0.355
m.Calculate the rear speed in the above
arrangement at the engine speed of 2500 rpm.
2. Sketch the section through the sliding type gear box
with a four forward and reverse speed explain clearly
hoe the different speed ratios will be obtained in the
following cases:
Gear ratio on the top gear = 1:1
Gear ratio on the 3rd gear = 1.38 : 1
Gear ratio on the 2nd gear = 2.24 : 1
Gear ratio on the 1st gear = 3.8:1
Gear ratio on the reverse gear = 3.8:1
Assume counter shaft or lay shaft speed is half that of
the engine speed and the smallest gear is not to have
less then 15 teeth.
3. An automotive gear box gives 3 speed and 1
reverse with a top gear of unity and bottom
and reverse gear ratio of approximately 3.3:1.
The center distance between the shafts is to be
110 mm approx. Gear teeth module 3.25 mm
are to be employed.
Sketch the layout of typical constant mesh gear
box for these condition giving the no. of teeth
for the various gear wheel and showing closely
hoe the different ratio are obtained.
Can use charts shown in 14-12 to get C. Or
equation presented earlier.
 CAREFUL!
• Previous equations assumes: L10 life, and
inner race rotates and radial load only!!

1. Inner race rotates, then Pd = P = V*R where V = 1.0 if inner

race rotates and V = 1.2 if outer race rotates.
2. Lar = CR * L10

Washing machine example, what if want 99% reliability??

3. What if thrust load is present??? - iteration

 P = VXR + YT
P = Load
V = Rotation Factor (1.0 – Inner Race, 1.2 – Outer Race)
X = Radial Factor (.56 if Y>0)
R = Applied Radial Load
Y = Thrust Factor
T = Applied Thrust Load

*Thrust Load Present – Deep Groove Ball Bearing

START FIND R,T Usually get for shaft analysis

ASSUME Y ~1.5 *Must initially guess

P=VXR+YT

C=PdfL/fN
Figure 14-12

Select Bearing
Table 14-3

Compute T/Co

Find e
Table 14-5 Iterate within reason
NO

YES
T/R>e? FIND Ynew Ynew =Yold?

NO
YES
P=VR

C=PdfL/fN END

Select Bearing END

Cont….
 PROGRESSION RATIO
We know that by using gear-box, we can obtain a
number of different speeds from a single motor
speed.
These speeds can be decided by employing a
constant, known as 'Progression ratio φ which is
the ratio of one speed to the next lower speed.
 Let N1 be the minimum speed, N2, N3, N4 be
the successive higher speeds, and N5 the
maximum speed, so that the total number of
speeds may be 5,
 DESIGN PROCEDURE:
The gears operated in a gear box may be
mostly the spur-gear type or helical gear type.
Combined form of spur with bevel or helical
with bevel are very rarely used especially for
specific functions such as to transmit power in
an angular directions in different speeds.
Gear box with a number of worm-gear drive
is not usually made. Among all the above
types of gears, the use of spur-gears is
immensive.
1. From the given problem, decide the amount of
power to be transmitted, motor speed, number of
speeds required, maximum and minimum speeds,
available space etc. For compact drive stronger
materials such as alloy steels may be selected,
usually all the gears may be made of same material.
3.Draw the speed diagram for which the number of shafts
are selected based on the gear ratio which should not be
more than four in a single step. The speeds of intermediate
shafts should be marked on them.
4.Draw the kinematic arrangement according to speed
diagram.
5.Compute the minimum centre distance between the
shafts based on surface compressive stress considering the
worst condition (i.e.., maximum power and lowest speed
condition). Usually, the determination of centre distance
should be started from the spindle shaft, and then the design
is proceeded to other shafts successively and
finally to the motor shaft.
6.Calculate the minimum module based on design bending
stress and standardise it using the table
PROBLEMES
Solution
PROBLEMES
Gear trains are widely used in all kinds of mechanisms and
machines, from can openers to aircraft carriers. Whenever a change
in the speed or torque of a rotating device is needed, a gear train or
one of its cousins, the belt or chain drive mechanism, will usually be
used.

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A variation on this mechanism is what causes your car or bicycle to move
along the road. Your tire is one rolling cylinder and the road the other
(very large radius) one. Friction is all that prevents slip between the two,
and it works well unless friction coefficient is reduced by the presence of
ice or other slippery substances.
A variant on the rolling cylinder drive is the flat or V belt. This
mechanism also transfers power through friction and is capable of quite
large power levels, provided enough belt cross section is provided.
Friction belts are used in a wide variety of applications from small sewing
machines to the alternator drive on your car, to multi horsepower
generators and pumps. Whenever absolute phasing is not required and
power levels are moderate, a friction belt drive may be the best choice.
They are relatively quiet running, require no lubrication, and are
inexpensive compared to gears and chain drives.

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 The principal drawbacks to the rolling cylinder drive (or smooth belt)
mechanism are its relatively low torque capability and the possibility of
slip.
“The angular velocity ratio between the gears of a gear-set
remains constant throughout the mesh.”

An external set reverses the direction of rotation between

the cylinders and requires the negative sign. An internal
Gear-set or a belt or chain drive will have the same direction
of rotation on input and output shafts and require the positive
sign .

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Circular Pitch:
The circular pitch is the arc length along the pitch circle circumference
measured from a point on one tooth to the same point on the next. The
circular pitch defines the tooth size.
where d = pitch diameter
and N = number of teeth.

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Base Pitch:
The tooth pitch can also be measured along the base circle circumference and then is
called the base pitch pb.

Diametral Pitch:
The diametral pitch pd is:
pd = N/d

Module:
It is the reciprocal of diametral pitch with pitch diameter measured in millimeters.
m = d/N
In terms of diameters and number of teeth, the Velocity and Torque ratios are:

Gear Ratio:
The gear ratio mG is always > 1 and can be expressed in terms of either the velocity ratio or torque
ratio depending on which is larger than 1. Thus mG expresses the gear train's overall ratio independent
of change in direction of rotation or of the direction of power flow through the train when operated
either as a speed reducer or a speed increaser.

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SPUR GEARS:
SPUR GEARS are ones in which the teeth are parallel to
the axis of the gear. This is the simplest and least
expensive form of gear to make. Spur gears can only be
meshed if their axes are parallel.
HELICAL GEARS:
HELICAL GEARS are ones in which the teeth are at
a helix angle ψ with respect to the axis of the gear.

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HERRINGBONE GEARS :
HERRINGBONE GEARS are formed by joining two helical
gears of identical pitch and diameter but of opposite hand on
the same shaft. These two sets of teeth are often cut on the
same gear blank.
WORMS AND WORM GEARS:
If the helix angle is increased sufficiently, the result will be a
worm, which has only one tooth wrapped continuously
around its circumference a number of times, analogous to a
screw thread. This worm can be meshed with a special worm gear
(or worm wheel), whose axis is perpendicular to that of the worm.
Because the driving worm typically has only one tooth, the ratio of
the gear-set is equal to one over the number of teeth on the worm
gear.

“Perhaps the major advantage of the worm-set is that it can

be designed to be impossible to back drive.”

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RACK AND PINION:
Sometimes, the gear of a shaft meshes externally and internally with the gears in
a straight line. Such type of gear is called rack and pinion. The straight line gear
is called rack and the circular wheel is called pinion. A little consideration will
show that with the help of a rack and pinion, we can convert linear motion into
rotary motion and vice-versa.

BEVEL GEARS:
For right-angle drives, crossed helical gears or a worm-set can be used. For any
angle between the shafts, including 90°, bevel gears may be the solution. Just as
spur gears are based on rolling cylinders, bevel gears are based on rolling cones .
The angle between the axes of the cones and the included angles of the cones can
be any compatible values as long as the apices of the cones intersect. If they did
not intersect, there would be a mismatch of velocity at the interface.

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SPIRAL BEVEL GEARS:
If the teeth are parallel to the axis of the gear, it will be a straight bevel
gear. If the teeth are angled with respect to the axis, it will be a spiral
bevel gear, analogous to a helical gear. The cone axes and apices must
intersect in both cases. The advantages and disadvantages of straight bevel
and spiral bevel gears are similar to those of the spur gear and helical gear,
respectively, regarding strength, quietness, and cost.

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