ID- 151- Engineering Mechanics

B.Sc. Industrial Engineering & Management

Semester: 1st 2019-2023

Lecture: 14
Date: 18-02-2020

EM-B.Sc (IEM)- 1st

1
 Topic

GEAR DRIVES
Reference:
1. Chapter# 12
[R.S.KHURMI] A Textbook of Theory of Machines
2. Chapter# 10
[David H. Myszka] MACHINES AND MECHANISMS
3. Chapter# 05
[Oleg Vinogradov] FUNDAMENTAL of KINEMATICS
And DYNAMICS of MACHINES and
MECHANISMS

EM-B.Sc (IEM)- 1st

2
 OBJECTIVES
Upon completion of this chapter, the student will be able to:
 Introduction to Gears
 Describe the advantages/disadvantages of a Chain drive.
 Identify the different types/Classifications of gears.
 Identify and use standard gear geometric features.
 Calculate center distance, contact ratio, interference
limitations, and backlash variations.
 Calculate and use the velocity ratio to determine the
kinematic properties of mating gears.

EM-B.Sc (IEM)- 1st

3
 Learning Tour
 Spur Gear Kinematics
 Gear Trains
-Types of Gear Trains

EM-B.Sc (IEM)- 1st

4
 Pressure Angle/Angle of Obliquity
 The pressure angle, φ, is the angle between a line tangent to both
pitch circles of mating gears and a line perpendicular to the surfaces of
the teeth at the contact point. The line tangent to the pitch circles is
termed the pitch line.
 The line perpendicular to the surfaces of the teeth at the contact point
is termed the pressure line or line of contact. Therefore, the
pressure angle is measured between the pitch line and the pressure
line.

EM-B.Sc (IEM)- 1st

5
 Pressure Angle/Angle of Obliquity
 The pressure angle affects the relative shape of a gear tooth. Although
gears can be manufactured in a wide range of pressure angles, most
gears are standardized at 20° and 25°.
 Gears with 141⁄2° pressure angles were widely used but are now
considered obsolete. They are still manufactured as replacements for
older gear trains still in use.
 Because the pressure angle affects the shape of a tooth, two mating
gears must also have the same pressure angle.

EM-B.Sc (IEM)- 1st

6
 Gear Mating Process

EM-B.Sc (IEM)- 1st

7
 Gear Teeth & Shape of Gears w.r.t DP, Pressure Angles

EM-B.Sc (IEM)- 1st

8
 Center Distance
The center distance, C ,is defined as the center-to-center
distance between two mating gears.
This is also the distance between the shafts that are carrying
the gears.
 For the common configuration
of external gears the distance can
be written as:
 For internal gears the
center distance is the difference
in the pitch radii.

EM-B.Sc (IEM)- 1st

9
 Center Distance- Example
Two 5-pitch,20°full-depth gears are used on a small construction site
concrete mixer. The gears transmit power from a small engine to the
mixing drum. The pinion has 15 teeth and the gear has 30 teeth.
 Determine the center distance.
Calculate Pitch Diameters
Calculate the Center Distance
Verify Center Distance

EM-B.Sc (IEM)- 1st

10
 Contact Ratio
 The contact ratio, mp, is the average number of teeth that are in contact at
any instant. Obviously the contact ratio must exceed 1 because contact between
gears must not be lost.
 In practice, contact ratios should be greater than 1.2.
 Robust designs have contact ratios of1.4 or 1.5. To illustrate the principle, a
contact ratio of 1.2 indicates that one pair of teeth is always in contact and a
second pair of teeth is in contact 20 percent of the time.
 Greater contact ratio values result in smoother action because another gear
tooth shares the load for a longer duration during the engaging/disengaging
process.
 In addition, with more teeth sharing the load, greater power may be
transmitted. However, the most direct manner in which the contact ratio can be
increased is to use larger gears.
 This is in direct contrast to most design goals of compactness.

EM-B.Sc (IEM)- 1st

11
 Contact Ratio
 Numerically, contact ratio can be expressed as the length of the path
of contact divided by the base pitch, pb.
 The base pitch, in turn ,is defined as the distance between
Corresponding points of adjacent teeth, measured on the base circle.
 The base pitch can be computed with the following:

 The length of this contact path, Z, is derived by the intersections of the

respective addendum circles and the contact line.

EM-B.Sc (IEM)- 1st

12
 Contact Ratio- Example
Two 5-pitch,20°full-depth gears are used on a small construction site
concrete mixer. The gears transmit power from a small engine to the
mixing drum. The pinion has 15 teeth and the gear has 30 teeth.
a) Calculate the Basic Tooth Properties
b) Addendum for 20°full-depth teeth
c) Calculate the Base Pitch
d) Calculate Contact Length
e) Calculate the contact ratio

EM-B.Sc (IEM)- 1st

13
 Backlash
 Backlash is the amount that the width of a tooth space exceeds the
thickness of a gear tooth, measured on the pitch circle.
 In more practical terms, it is the amount that a gear can turn without its
mating gear turning.
 Although backlash may seem undesirable, some backlash is
necessary to provide for lubrication on the gear teeth.
 Gears that run continuously in one direction can actually have
considerable backlash.
 Gears that frequently start/stop or reverse direction should have
closely controlled backlash.
 A nominal value of backlash is designed into a gear tooth profile. The
amount of backlash determines the thickness of a gear tooth because
backlash is a measure of the tooth thickness to the tooth space.

EM-B.Sc (IEM)- 1st

14
 Backlash

EM-B.Sc (IEM)- 1st

15
 Backlash

EM-B.Sc (IEM)- 1st

16
 Backlash Standard Values
 Recommended values of backlash are specified by AGMA [Standard
2002-B88].
 Although these values are somewhat conservative, general power
transmitting gears have recommended backlash values of:

 For commercially available stock gears, backlash values are

Considerably higher to allow for greater flexibility in applications.
The backlash values of these gears are typically:

EM-B.Sc (IEM)- 1st

17
 Backlash & Center Distance
 Backlash values are strongly influenced by any variation in
the center distance of the gears.
 The backlash variation ΔB that will be encountered with a
variation in the center distance ΔC can be approximated
by the following relationship:

Above equation can be used with equation to specify a

center distance that produces backlash values to be
maintained in the range given.
 Reducing the center distance reduces the backlash, and
vice versa.

EM-B.Sc (IEM)- 1st

18
 Backlash- Example
The gears for the concrete mixer described in Example Problem 10.3 are
catalog items with a designed backlash of0.4/Pd.
Specify a center distance that reduces the backlash to an AGMA
recommended value of0.1/Pd.

Calculate Designed Backlash

Calculate Recommended Backlash
Calculate the Adjusted Center Distance

From Example Problem 10.3,the nominal center distance was

determined
as 4.5 in. Therefore, to adjust the backlash value, the center distance
should be reduced to:
C adjusted = 4.5 - 0.0824 = 4.4176in.

EM-B.Sc (IEM)- 1st

19
 Backlash- Point to Ponder
 Reducing the center distance will produce an
overly tight mesh and may produce excessive
noise, overheating, and structural overload.
 However, some applications require minimal
backlash.
 Of course, testing should be conducted to confirm
the design.

EM-B.Sc (IEM)- 1st

20
 Operating Pressure Angle
 The pressure angle defines the line of action of the force onto
the gear teeth. This reflects the actual performance of the gear
forces.
 The designated pressure angle is cut or formed into the gear
tooth and affects the actual shape of the tooth.
 It should be mentioned that as the center distance of the
mating gears deviates from the nominal value, the actual pressure
angle during operation differs from the designated value.
 In other words, two 20°gears may actually have a greater
pressure angle during operation by increasing the center distance
from the nominal value.
 The relationship that can be used to determine the amount of
variance is derived as:

EM-B.Sc (IEM)- 1st

21
 Operating Pressure Angle- Example
For the gears of the concrete mixer described in
Example Problem.
 Determine the operating pressure angle when the
center distance is measured at 4.4176.

EM-B.Sc (IEM)- 1st

22
 Spur Gear Kinematics
 A basic function of gears is to provide a constant velocity ratio between
their respective shafts. A pair of gears that has a constant velocity ratio
means that the driven gear maintains a uniform speed as long as the
driver gear rotates at a constant speed. This condition led to the
development of the involute tooth profile.
 Formally, the velocity ratio, VR, is defined as the angular speed of the
driver gear (gear 1) divided by the angular speed of the driven gear
(gear 2).

EM-B.Sc (IEM)- 1st

23
 Gear Ratios
Variables to know
n = number of teeth 4”
d = diameter
w = angular velocity (speed)
t = torque
** Subscripts in and out are used to distinguish
between gears **

nin= 6 nout = 12
din = 2in. dout = 4in.
win = 40rpm wout = 20rpm
t = 40 ft-lb
in
t = 80 ft-lb
out
 Gear Ratios
Equations to know
GR = Gear Ratio

GR n out d out in out

   
1 n in d in out in

? 12 4in. 40rpm 80 ft  lb
1 6 2in. 20rpm 40 ft  lb
2
1 EM-B.Sc (IEM)- 1st
25
 Gear Ratios

What is the gear ratio GR n out 12 .6

  
between gear A and B? 1 n in 20 1

GR n out 5 .42
What is the gear ratio between   
gear B and C? 1 n in 12 1

What is the gear ratio GR n out 20 4

between gear C and   
1 n in 5 1
D?
EM-B.Sc (IEM)- 1st
26
 Gear Ratios
Idler gears don’t affect GR!

0.6 0.42 4 1
What is the TOTAL gear train   
gear ratio? 1 1 1 1

If gear A and D were directly GR n out 20 1

  
connected to each other, what 1 n in 20 1
would the resulting gear ratio be?
What would the total gear ratio be if the last gear had 40 teeth?
0.6 0.42 8 2 GR n out 40 2
     
1 1 1 1 1 n in 20 1

EM-B.Sc (IEM)- 1st

27
 Spur Gear Kinematics
 In practice, a velocity ratio of 3 would be indicated as 3:1 and
pronounced “three to one.” Likewise, a velocity ratio of 1/3 would be
indicated as 1:3 and pronounced “one to three.”
 The pitch line velocity, vt, is defined as the magnitude of the velocity of
the pitch point of the two mating gears.
 It should be apparent that the pitch line velocity of both gears is identical
because one gear tooth pushes the mating tooth.
 Introducing the pitch diameters,

EM-B.Sc (IEM)- 1st

28
 Spur Gear Kinematics
 An algebraic sign convention designates the relative direction of gear
rotations. In the typical external gear set, the shaft centers are on
opposite sides of the common tangent to the pitch circles, which
dictates that the gears rotate in opposite directions. To signify this fact,
the velocity ratio is given a negative value.
 The shaft centers are on the same side of the common tangent to the
pitch circles. This dictates that the gears rotate in the same direction.
Thus, the velocity ratio is given a positive value.

EM-B.Sc (IEM)- 1st

29
 Spur Gear Kinematics- Example
 A set of gears is used to reduce the speed from an electric motor to a shaft
driving a grocery checkout conveyor (Figure 10.13). The gear on the motor
shaft is a 10-pitch pinion, has 15 teeth, and drives at 1800 rpm clockwise.
 Determine the speed of the mating gear, which has 45 teeth. Also
calculate the pitch line velocity.

EM-B.Sc (IEM)- 1st

30
 Spur Gear Kinematics- Example
 Calculate the Velocity Ratio

 Calculate the Rotational Velocity of the Driven Gear

 Calculate the Pitch Line Velocity

EM-B.Sc (IEM)- 1st

31
 Gear Train
 Gear train is a series of mating gear sets. Gear trains are commonly
used to achieve large speed reductions.
 Many mechanical power sources, such as engines, turbines, and
electric motors, operate efficiently at high speeds (1800–10,000 rpm).
 Many uses for this power, such as garage door openers, automotive
drive wheels, and ceiling fans, require low speeds (10–100 rpm) for
operation. Therefore, a desire to achieve large-velocity reductions is
common, and the use of gear trains is very common.

EM-B.Sc (IEM)- 1st

32
 Reason to develop Gear Train
 For example, it may be desired to reduce the speed of a
shaft from 1800 rpm to 10 rpm. Thus, a velocity reduction of
180:1 is required. If this reduction were attempted with one
gear set, below equation would reveal that the driven gear
would be 180 times larger than the drive gear. Obviously,
the driven gear would be tremendously large, heavy, and
expensive.
 A second, more logical option is to reduce the speed in
steps, through a series of gear pairs. This strategy
cascades the rotational velocities toward the desired output
velocity. This is exactly the logic behind gear trains.

EM-B.Sc (IEM)- 1st

33
 Gear Train- Train Value
 When multiple gear pairs are used in a series, the overall velocity ratio
is termed a train value—TV. The train value is defined as the input
velocity to the gear train divided by the output velocity from the train.
 This is consistent with the definition of a velocity ratio. A train value is
the product of the velocity ratio of the individual mating gear pairs that
comprise the train. In equation form, it is stated a

 The algebraic sign resulting from the multiplication of individual velocity

ratios determines the relative rotational direction of input and output
shafts.
 Positive values reveal that the input and output shafts rotate in the
same direction, and negative values indicate opposite rotation.

EM-B.Sc (IEM)- 1st

34
 Types of Gear Trains
Following are the different types of gear trains, depending
upon the arrangement of gears:

1. Simple gear train

2. Compound gear train
3. Reverted gear train
4. Epicyclic gear train

EM-B.Sc (IEM)- 1st

35
 Simple Gear Train
Input and Output Shafts
Driven / Output parallel (A & B)
A. Drive / Input A – Ratio 1:1 [Output to Input]
Speed is constant
Torque is constant

B – Ratio 3:5 [Output to Input]

Driven / output 36 teeth : 60 teeth
Speed is increased
B. Drive / Input
Torque is decreased
Flow of power - reversible
Motion - rotational to rotational
Direction – opposite

EM-B.Sc (IEM)- 1st

36
 Where Do You Find a Simple Gear Train?
Found in:
– Watch
– Sewing Machine
– Motor

Watch gears

Two meshed gears will rotate

in opposite directions

EM-B.Sc (IEM)- 1st

37
 Simple Gear Train with Idler
Idler Drive / Input
Driven / Output
EM-B.Sc (IEM)- 1st
38
Input and Output Shafts
parallel
Ratio 1:1 [Output to Input]
Speed is constant
Torque is constant
Flow of power - reversible
Motion - rotational to
rotational to rotational
Direction – same
 Where Do You Find a Simple Gear Train with Idler?
Two meshed gears will rotate in
opposite directions.

An Idler Gear allows the drive and

driven gears to rotate in the same
direction.
7. Found in - Paper Transport
Rollers / Car Transmission

EM-B.Sc (IEM)- 1st

39
 Bevel Gear
Input and Output Shafts
90 degrees
Ratio 1:1 [Output to Input]
Speed is constant
Torque is constant

Flow of power - reversible

Motion - rotational to
rotational
Direction – same

EM-B.Sc (IEM)- 1st

40
 Differential Gear
1. Gears used – Bevel
2. Used in – rear end of rear wheel drive vehicles
3. Purpose – Wheels spin at different speeds
when turning
http://auto.howstuffworks.com/differential.htm

EM-B.Sc (IEM)- 1st

41
 Worm and Wheel
Input and Output Shafts
90 Degrees
Ratio 1:24 [Output to Input] Wheel
Speed is decreased
Torque is increased

Flow of power – not

reversible
Motion - rotational to
rotational
Direction – same & reversible

Worm

EM-B.Sc (IEM)- 1st

42
 Where Do You Find a Worm and Wheel?
Found in:
• Tuning mechanism on string
instruments
• Electric motors
• Winch

A worm is used to reduce

speed and increase torque.

EM-B.Sc (IEM)- 1st

43
 Rack and Pinion
Pinion Force increased
Input Movement rotary
Output Movement
linear
With a Larger Pinion Gear -
the rack will move a longer
distance
Flow of power - reversible
Motion - rotational to linear
Direction – same & Reversible

Rack

EM-B.Sc (IEM)- 1st

44
 1- Simple Gear Train
 When there is only one gear on each shaft, simple gear train. The
gears are represented by their pitch circles. When the distance
between the two shafts is small, the two gears 1 and 2 are made to
mesh with each other to transmit motion from one shaft to the
other.
 Since the gear 1 drives the gear 2, therefore gear 1 is called the
driver and the gear 2 is called the driven or follower.
 It may be noted that the motion of the driven gear is opposite to the
motion of driving gear.

EM-B.Sc (IEM)- 1st

45
 Simple Gear Train- Analysis
 The train value is the reciprocal of speed ratio.

EM-B.Sc (IEM)- 1st

46
 Simple Gear Train Ratios
 Ratios Gears of the same pitch, but differing numbers of teeth can
be paired to obtain a wide range of Gear Ratios.
 Gear Ratios are used to increase mechanical advantage (torque)
or increase rotational speed or velocity.
 “Low” Gearing to increase torque
 “High” Gearing to increase Driven Gear Velocity

EM-B.Sc (IEM)- 1st

47
 Simple Gear Train- Idler Gears
 Sometimes, the distance between the two gears is large. The motion from one
gear to another, in such a case, may be transmitted by either of the following
two methods :
 By providing the large sized gear, or
 By providing one or more intermediate gears.
 These intermediate gears are called idle gears, as they do not affect the
speed ratio or train value of the system. The idle gears are used for the
following two purposes:
 To connect gears where a large centre distance is required, and
 To obtain the desired direction of motion of the driven gear (i.e.
clockwise or anticlockwise).

EM-B.Sc (IEM)- 1st

48
 2- Compound Gear Train
 When there is more than one gear on a shaft, it is called a compound
train of gear.
 We have seen in previous section that the idle gears, in a simple train
of gears do not affect the speed ratio of the system. But these gears
are useful in bridging over the space between the driver and the driven.
 But whenever the distance between the driver and the driven or
follower has to be bridged over by intermediate gears and at the same
time a great ( or much less ) speed ratio is required, then the advantage
of intermediate gears is intensified by providing compound gears on
intermediate shafts.

EM-B.Sc (IEM)- 1st

49
 Compound Gear Train
 In this case, each intermediate shaft has two gears rigidly fixed to
it so that they may have the same speed. One of these two gears
meshes with the driver and the other with the driven or follower
attached to the next shaft

EM-B.Sc (IEM)- 1st

50
 Compound Gear Train
Driver The two middle gears share
a common axle, so they
rotate at the same speed.
This allows the final gear to
rotate slower and produce
more torque than if it were
connected only to the driver
gear.

EM-B.Sc (IEM)- 1st

51
 Compound Gear Ratios
D
B
C A

20 10
T What is the gear ratio
T40 T
50 T between gear A and B?
GR nout 40 4
What is the gear ratio between   
gear C and D? 1 nin 10 1
GR nout 50 2.5
  
1 nin 20 1
What is the gear ratio of 4 2.5 10
 
the entire gear train? 1 1 1
EM-B.Sc (IEM)- 1st
52
 Compound Gear Train- Example
 The gearing of a machine tool is shown in Fig. 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:

EM-B.Sc (IEM)- 1st

53
 Compound Gear Train- Example
Solution: Given: NA=975 r.p.m.; TA=20; TB=50; TC=25; TD=75;
TE=26; TF=65

EM-B.Sc (IEM)- 1st

54
 3- Reverted Gear Train
 When the axes of the first gear (i.e. first driver) and the last gear (i.e. last driven or follower) are
co-axial, then the gear train is known as reverted gear train
 We see that gear 1 (i.e. first driver) drives the gear 2 (i.e. first driven or follower) in the opposite
direction. Since the gears 2 and 3 are mounted on the same shaft, therefore they form a
compound gear and the gear 3 will rotate in the same direction as that of gear 2. The gear 3
(which is now the second driver) drives the gear 4 (i.e. the last driven or follower) in the same
direction as that of gear 1.
 Thus we see that in a reverted gear train, the motion of the first gear and the last gear is like.
 The reverted gear trains are used in automotive transmissions, lathe back gears, industrial
speed reducers, and in clocks (where the minute and hour hand shafts are co-axial).

EM-B.Sc (IEM)- 1st

55
 3- Reverted Gear Train

EM-B.Sc (IEM)- 1st

56
 More Complex

EM-B.Sc (IEM)- 1st

57
 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
r1 + r2 = r3 + r4
 Also, the circular pitch or module of all the gears is assumed to be
same, therefore number of teeth on each gear is directly proportional
to its circumference or radius.

EM-B.Sc (IEM)- 1st

58
 4- Epicyclic/ Planetary gear train
 The gear trains presented in preceding sections all had gear centers attached to
fixed bodies. With planetary gear trains, this restriction is removed. In these
trains, a link that holds the center of the gears is allowed to move. A planetary
gear train, which is also called an epicyclic train.
 Planetary trains can be used to achieve large speed reductions in a more
compact space than a conventional gear train. However, a greater benefit is the
ability to readily alter the train value. Because all links are capable of moving,
one can alter the train value by holding different gears or carriers. In practice,
switching the fixed link is accomplished with brake or clutch mechanisms, thus
releasing one link and fixing another. For this reason, planetary gear trains are
very common in automotive transmissions.

EM-B.Sc (IEM)- 1st

59
 Epicyclic/ Planetary gear train
 Because the motion can resemble the planets rotating about the sun in
our solar system, the term planetary gear train was applied to this
system. Expanding on this comparison, the center gear is called the
sun.
 Gears that revolve around the sun are called planets. A carrier holds
the planet gears in orbit around the sun.
 Finally, the train is commonly encased in the internal gear termed the
ring gear.

Understanding PLANETARY GEAR set ! - YouTube.mkv

EM-B.Sc (IEM)- 1st

60
 Comparison b/w gear trains
Simple gear train Compound gear train
 Only one gear in
each shaft and there  In this gear there is
is a relative motion more than one gear
between shaft axis. on the shaft which is
rigidly fix and mashed
 For large speed with the gear on
reduction, large size another shaft forming
of gear is required. gear train
 For large speed
reduction the small
gear ratio is required..
EM-B.Sc (IEM)- 1st
61
Elliptical gear train
 The axis of shaft on
which the gear are
mounted may move
relative to the fixed
axis.
 For large speed
reduction in
high velocity moderate
size gear is required.
 Automotive Gears

EM-B.Sc (IEM)- 1st

62