DJJ 10033

WORKSHOP TECHNOLOGY

CHAPTER 5: GEAR

Prepared by:
Mohd Zulfadli bin Ahmad
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify the types of gears & their function

 Differentiate the type of gears, the characteristic
and uses
 Classify parts of a spur gear such as addendum,
dedendum, pitch diameter, pitch circle,
dedendum circle and etc and its specification
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify the types of gears & their function

 Differentiate the type of gears, the characteristic
and uses
 Classify parts of a spur gear such as addendum,
dedendum, pitch diameter, pitch circle,
dedendum circle and etc and its specification
 Spur Gear

Characteristic:
 Spur gears are the most commonly used gear
type. They are characterized by teeth which are
perpendicular to the face of the gear.
 Spur gears are by far the most commonly
available, and are generally the least expensive.
 Spur Gear

Features
1) Easy to manufacture
2) There will be no axial force
3) Relatively easy to produce high quality gears
4) The commonest type

Application
 Transmission component
Helical Gear

Characteristic:
 Helical gears are similar to the spur gear except
that the teeth are at an angle to the shaft, rather
than parallel to it as in a spur gear.
 The resulting teeth are longer than the teeth on a
spur gear of equivalent pitch diameter.
 Helical Gear
Characteristic:
 The longer teeth cause helical gears to have the
following differences from spur gears of the
same size:
 Tooth strength is greater because the teeth are
longer
 Greater surface contact on the teeth allows a
helical gear to carry more load
 The longer surface of contact reduces noise and
vibration compared with spur gear

Application
Transmission components, automobile,
speed reducers etc
 Racks

Characteristic:
 The racks is a bar containing teeth on one face for
meshing with a gear.
 It is a straight gears that are used to convert
rotational motion to translational motion by means
of a gear mesh.
 Racks
Application:
 Well-known in rack & pinion steering system use
on many cars.
 A transfer system for machine tools, printing press,
robot, etc
 Bevel Gear

Characteristic:
 Bevel gears are primarily used to transfer power
between intersecting shafts. The teeth of these
gears are formed on a conical surface.
 Straight bevel gears have teeth which are cut
straight and are all parallel to the line pointing the
the apex of the cone on which the teeth are based.
 Spiral bevel gears are also available which have
teeth that form arcs.
 Bevel Gear

Straight bevel
Spiral bevel

Application:
 Common application: bevel gear differential unit
 A transfer system for machine tools, printing press
etc
 Worm Gear

Characteristic:
 Worm gears are special gears that resemble
screws, and can be used to drive spur gears or
helical gears.
 Worm gears, like helical gears, allow two non-
intersecting 'skew' shafts to mesh. Normally, the
two shafts are at right angles to each other. A
worm gear is equivalent to a V-type screw thread.
 Worm Gear
 Worm gears are normally used when a high gear
ratio is desired, or again when the shafts are
perpendicular to each other.
 One very important feature of worm gear meshes
that is often of use is their irreversibility : when a
worm gear is turned, the meshing spur gear will
turn, but turning the spur gear will not turn the
worm gear. The resulting mesh is 'self locking‘.

Application:
 Speed reducers, anti-reversing gear device
making the most of its self-locking indexing device,
chain block etc
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify the types of gears & their function

 Differentiate the type of gears, the characteristic
and uses
 Classify parts of a spur gear such as addendum,
dedendum, pitch diameter, pitch circle,
dedendum circle and etc and its specification
Parts of spur gear
Parts of spur gear
Parts of spur gear
Parts of spur gear
 Parts of spur gear

Term Definition Calculation

The diameter of the Pitch Circle from
Pitch which the gear is designed. An
PD = N_
Diameter imaginary circle, which will contact
DP
(PD) the pitch circle of another gear when
in mesh.
A ratio of the number of teeth per
Diametral DP = _ N_
inch or per centimeter of pitch
Pitch (DP) PD
diameter
Unit of size to indicate how big or M = PD_
Module (M)
small teeth N
Addendum The radial distance from the pitch
A=M
(A) circle to the top of the gear tooth
Dedendum The radial distance from the pitch
D = 1.666 M
(D) circle to the bottom of the tooth
 Parts of spur gear
Term Definition Calculation
The measured distance along the
circumference of the Pitch Diameter
Circular Pitch
from the point of one tooth to the CP = πM
(CP)
corresponding point on an adjacent
tooth.
Circular Thickness of a tooth measure along T = 1.57 M
Thickness (T) the circumference of the Pitch Circle
Refers to the radial distance
Clearance (C) between the top and bottom of gears C = 0.157 M
in mesh.
Outside
Diameter The overall diameter of the gear OD = (N+2) x M
(OD)
The center distance of 2 spur gears
Center is the distance from the center shaft CD = PDA + PDB
Distance (CD) of one spur gear to the center shaft
of the other.
 Lets Do It !!
 A spur gear consist pitch diameter (PD)
50mm and 20 gear teeth. It mesh with
another spur gear with 30mm pitch
diameter (PD). Find out:

a) Module,M [2.55mm]
b) Circular pitch,CP [7.85mm]
c) Addendum,A [2.5mm]
d) Outer Diameter,OD [55mm]
e) Dedendum,D [4.165mm]
f) Center Distance, CD [40mm]
g) Clearance,C [0.4mm]
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify a spur gear

 Describe method to measure and inspect chordal
thickness using a gear tooth vernier caliper
 Describe method to inspect the pitch diameter for
a spur gear using a micrometer and rollers
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify a spur gear

 Describe method to measure and inspect chordal
thickness using a gear tooth vernier caliper
 Describe method to inspect the pitch diameter for
a spur gear using a micrometer and rollers
 Tooth Vernier Caliper

To measure chordal thickness, a vernier tooth calliper

is commonly used.
 Tooth Vernier Caliper
Procedure: -
 The gear tooth vernier has two vernier scales and
they are set for width ‘W’ of the tooth and depth ‘d’
from the top at which ‘W’ occurs.
 Consider one gear tooth, the values of ‘W’ and ‘d’ can
be found by using caliper. It may be noted that ‘w’ is
chord length but tooth thickness is specified by arc
distance.
 Also ‘d’ found out by using caliper is slight greater
than addendum.
 Therefore ‘W’ and‘d’ are called chordal thickness and
chordal addendum respectively.
Chordal Thickness
 Chordal Thickness

Chordal thickness, TD

TD = 2MQ

where;
m = module pitch
R = pitch circle radius
T = no of teeth of the gear
 Chordal Thickness

Height, h

Height, h = MP = OP-OM

where;
P @ DP =diametral pitch = 1/M
T = no of teeth of the gear
 Self Assesment !!
 Calculate gear tooth vernier setting [w&h]
to measure a gear of 33T, 6 module.
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Classify a spur gear

 Describe method to measure and inspect chordal
thickness using a gear tooth vernier caliper
 Describe method to inspect the pitch diameter for
a spur gear using a micrometer and rollers
 Pitch Diameter Inspection
 To inspect the pitch diameter for a spur gear, a roller
was used with an outer micrometer.
 Centre roller must be suitable with pitch and pressure
angle for testing gear.
 If number of teeth is even, the roller need to be put
on opposite
 For gears having odd number of teeth, roller are
placed as nearly opposite as possible
Pitch Diameter Inspection
(Plug Method)

In triangle OBD: OB = radius of plug required

OD = (1/4) circular pitch
= (πM/4) cos ψ

Diameter of plug = 2OD

= (πM/2) cos ψ

Where; M:module
ψ: pressure angle PD = MN
 Lets Solve It!!
Calculate for a 36T of 5mm module and 20° pressure angle.
a) plug size
b) distance over two plugs placed in opposite spaces

Solutions:

a) Dia of plug = (πM/2) cos ψ

= (5π/2) cos 20
= 7.854 x 0.9397
= 7.38 mm

Pitch dia of gear = MN

= 5 x 36
= 180 mm

b) Distance across plugs in opposite spaces

= 180 + 7.38 = 187.38 mm
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Explain method of milling a spur gear using

indexing head
 Direct indexing
 Simple indexing
 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Explain method of milling a spur gear using

indexing head
 Direct indexing
 Simple indexing
 Indexing

The indexing or dividing head is one of the most

important attachments for the milling machine.

It used to divide circumference of a workpiece into

equally spaced divisions when milling gears.

May also used to rotate the wokpiece at a

predetermined ratio to the table feed rate to produce
cams and helical groove on gears.
 Direct Indexing
 is the simplest form of indexing
 perform by disengaging the worm shaft from the
worm wheel by means of eccentric device in the
dividing head.
 Some direct dividing heads do not have a worm or a
worm wheel but rotate on bearings.
 The index plate contains slots (which numbered) and
a spring-loaded tongue lock (to engage in the proper
slot)
 DI used for quick indexing of the workpiece when
cutting.
 Direct Indexing
 work is rotated the required amount and held in place
by a pin that engage into a hole or slot in the direct
indexing plate mounted on the end of the dividing
head spindle.
 Direct indexing head: 3 set of hole circle/slot
(24,30,36)
 Common division that can be obtained by direct
indexing as below:
 Question??
What direct indexing is necessary to mill nine flutes on a
spur gear?

Solution:

Since the 36-hole circle is the only one divisible by 9.

Indexing = 36/9 = 4 hole on a 36-hole circle

 Learning Outcome

Upon completion of this chapter, students should

be able to:-

 Explain method of milling a spur gear using

indexing head
 Direct indexing
 Simple indexing
 Simple Indexing

 work is positioned by means of the crank, index plate

and sector arms.
 The worm attached to the crank must be engage with
the worm wheel on the dividing head spindle.
 Since there are 40 teeth on the worm wheel, one
complete turn of the index crank will cause the
spindle and the work to rotate one-fortieth or a turn.
 Similarly, 40 turns of the crank will rotate the spindle
and work 1 turn.
 Thus, there is a ratio of 40:1 between the turns of the
index crank and the dividing head spindle
 Simple Indexing
 To calculate the indexing or the number of turns of
the crank for most division, its necessary only to
divide 40 by the number of divisions (N) to be cut, or
Indexing = 40/N

The indexing required to cut eight flutes would be:

40/8 = 5 full turns of the index crank

If it were necessary to cut seven flutes, the indexing

would be
40/7= 5 5/7 turns
Five complete turns are easily made: however the five-
sevenths of a turn involves the use of the index plate
and sector arms.
 Simple Indexing
 To calculate the indexing or the number of turns of
the crank for most division, its necessary only to
divide 40 by the number of divisions (N) to be cut, or
Indexing = 40/N

The indexing required to cut eight flutes would be:

40/8 = 5 full turns of the index crank

If it were necessary to cut seven flutes, the indexing

would be
40/7= 5 5/7 turns
Five complete turns are easily made: however the five-
sevenths of a turn involves the use of the index plate
and sector arms.
Simple Indexing
THANK YOU…