GEAR AND GEAR

UNIT DESIGN

NAME: ADITYA V S S REGN. NO.: 317507005001 4/6 MECHANICAL ENGINEERING

ANDHRA UNIVERSITY COLLEGE OF ENGINEERING(A) , VISAKHAPATNAM

INTRODUCTION TO GEAR AND GEAR UNIT DESIGN

Gears are defined as toothed wheels or multilobed cams, which transmit power and
motion from one shaft to another by means of successive engagement of teeth.

Gear drives offer the following advantages compared with chain or belt drives:

1. It is a positive drive and the velocity ratio remains constant

2. The centre distance between the shafts is relatively small, which results in
compact construction.
3. It can transmit very large power, which is beyond the range of belt or chain
drives.
4. It can transmit motion at very low velocity, which is not possible with the belt
drives.
5. The efficiency of gear drives is very high even up to 99 per cent in case of spur
gears.
6. A provision can be made in the gearbox for gear shifting, thus changing the
velocity ratio over a wide range.
Gear drives are, however, costly and their maintenance cost is
also higher. The manufacturing processes for gears are
complicated and high specialized. Gear drives require careful
attention for lubrication and cleanliness. They also require
precise alignment of the shafts.
Addendum circle: The outer circle touching the outermost points of the teeth
Pitch circle: The imaginary rolling circle produced during rotation by mating gears
Base circle or root circle: The circle from which the involute tooth profile is developed
Dedendum circle: The circle touching the bottom of the tooth profile
Addendum: The radial distance for which the tooth profile is extended outward beyond the
pitch circle from the pitch circle
Dedendum: The radial distance for which the tooth profile is extended inward from the pitch
circle from the pitch circle
Pitch Point: The point of tangency of two gear Pitch Circles, through the Line of Centers.
Line of Action: A line tangent to the Base Circles of mating gears, through the Pitch Point and
thus the path of tooth contact.
Pressure Angle: The angle formed between the Line of Action and a line tangent to the Pitch
Point.
Tooth Thickness: The thickness of the gear tooth measured along the Pitch Circle.
Circular Pitch: The length of the arc along the Pitch Circle between corresponding points of
adjacent teeth.
Face Width: The width of gear tooth measured axially.
Tooth Face: The mating surface of a gear tooth between the addendum circle and the pitch
circle.
Tooth Flank: The mating surface of a gear tooth measured between the pitch circle and the
base circle.
Backlash: Amount of clearance between mated gear teeth.
 LAW OF GEARING

"The law of gearing states that the angular velocity ratio of all Gears of a
meshed gear system must remain constant also the common normal at the
point of contact must pass through the pitch point."
INTERFERENCE AND UNDERCUTTING
Gear tooth has involute profile only outside the base circle. In fact, the involute
profile begins at the base circle. In some cases, the dedendum is so large that it
extends below this base circle. In such situations, the portion of the tooth below the
base circle is not involute. The tip of the tooth on the mating gear, which is involute,
interferes with this non-involute portion of dedendum. This phenomenon of tooth
profiles overlapping and cutting into each other is called 'interference'. In this case,
the tip of the tooth overlaps and digs into the root section of its mating gear.
Interference is nonconjugate action and results in excessive wear, vibrations, and
jamming.
When the gears are generated by involute rack cutters, this interference is
automatically eliminated because the cutting tool removes the interfering portion of
the flank. This is called 'undercutting'. Undercutting solves the problem of
interference. However, undercut tooth is considerably weaker. Undercutting not only
weakens the tooth, but also removes a small involute portion adjacent to the base
circle. This loss of involute profile may cause a serious reduction in the length of
contact.

BACKLASH
Backlash is defined as the amount by which the width of tooth space exceeds the
thickness of the engaging tooth measured along the pitch circle. In general, backlash
is the play between mating teeth and it occurs only when teeth are in mesh .
 ASSUMPTIONS
(i) As the point of contact moves, the magnitude of
resultant force Py changes. This effect is neglected in the
above analysis.
FORCE (ii) It is assumed that only one pair of teeth takes the entire
ANALSYS load. At times there are two pairs, which are
simultaneously in contact and share the load. This aspect is
neglected in the analysis.

(iii) The analysis is valid under static conditions, i.e. when

the gears are running at very low velocities. In practice,
there is dynamic force in addition to force due to power
transmission. The effect of this dynamic force is neglected
in the analysis.
FORCES ACTING IN GEAR PINION MECHANISM
 Now let kW be the power transmitted, n be the rpm of the gear

where Mt is the torque transmitted.

Let Pt be the tangential component of force, Pr radial and Pn normal.

 GEAR TOOTH FAILURES
There are two basic modes of gear tooth failure -breakage
of the tooth due to static and dynamic loads and the
surface destruction. The complete breakage of the tooth
can be avoided by adjusting the parameters in the gear
design, such as the module and the face width, so that
the beam strength of the gear tooth is more than the sum
of static and dynamic loads. The surface destruction or
tooth wear is classified according to the basis of their
primary causes. The principal types of gear tooth wear are
as follows:
(1) Abrasive wear Foreign particles in the lubricant, such as dirt, rust,
weld spatter, or metallic debris can scratch or brinell the tooth
surface. Remedies against this type of wear are provision of oil filters,
increasing surface hardness, and use of high viscosity oils. Thick
lubricating film developed by these oils allows fine particles to pass
without scratching

(ii) Corrosive wear The corrosion of the tooth surface is caused by

corrosive elements, such as extreme pressure additives present in
lubricating oils and foreign materials due to external contamination.
These elements attack the tooth surface, resulting in fine wear
uniformly distributed over the entire surface. Remedies against this
type of wear are, providing complete enclosure for the gears free
from external contamination, selecting proper additives. and
replacing the lubricating oil at regular intervals.
(iii) Initial pitting The initial or corrective pitting is a localized
phenomenon, characterized by small pits at high spots. Such high spots
are progressively worn out and the load is redistributed. Initial pitting is
caused by the errors in tooth profile, surface irregularities and
misalignment. The remedies against initial pitting are precise machining
of gears, adjusting the correct alignment of gears so that the load is
uniformly distributed across the full face width, and reducing the
dynamic loads.
(iv) Destructive pitting is a surface fatigue failure, which occurs when
the load on the gear tooth exceeds the surface endurance strength of
the material. It is characterized by pits, which continue to grow
resulting in complete destruction of the tooth surface and, in some
cases, even premature breakage of the tooth. It depends upon the
magnitude of the Hertz' contact stress and the number of stress cycles.
This can be avoided by designing the gears in such a way that the wear
strength of the gear tooth is more than the sum of static and dynamic
loads. The surface endurance strength can be improved by increasing
the surface hardness.
iv) Scoring Excessive surface pressure, high surface speed and
inadequate supply of lubricant result in the breakdown of the oil film.
This results in excessive frictional heat and overheating of the meshing
teeth. Scoring is a stick-slip phenomenon, in which alternate welding
and shearing takes place rapidly at the high spots. Here the rate of
wear is faster. Scoring can be avoided by selecting the parameters,
such as surface speed, surface pressure and the flow of lubricant in
such a way that the resulting temperature at the contacting surfaces is
within permissible limits. The bulk temperature of the lubricant can be
reduced by providing fins on the outside surface of the gear box and a
fan for forced circulation of air over the fins.
 DESIGN OF GEAR

The face width b : 8m < b < 12m

BEAM LEWIS FORM FACTOR
STRENGTH
CRITERION
Pt = m b ((Sut)/3) Y

here Y = Lewis form factor

Cs = service factor
Cv= velocity factor
 MODULE

m=
WEAR STRENGTH CRITERION

Where,
Wear strength
MODULE
•Using the formula for
molecule given above with
respect to the selected
criterion off strength ,we
find out the dimensions of
the gear using the relations
given above .