GEAR FORCES Spur Gears Gears are used to transmit force and motion from one shaft to the

other. Circular gears are represented by circular blanks, called pitch circles. Pitch circles are tangent to each other at the pitch point. The kinematic requirement is that distance between the axes of the mating gears should be constant, because shafts carrying the gears are connected to the fixed link by bearings.

space width top land tooth thickness addendum circle face width face flank addendum dedendum dedendum circle Circular pitch clerance Base circle bottom land pitch circle

In theory, one blank transmit force and motion via the friction force occurring at the pitch point. There must be no slip between the two blanks at the pitch points. Blanks roll but do not slip with respect to each other. Input /output relationship for circular gear is linear. So:

.
.

VI23 r2 I12

3 I23 I13
Pitch point

r3
Pitch Circle

2 1

V I 23 = 2 * r2 and
,

V I 23 = 3 * r3 Then
, , ,

2 * r2 = 3 * r3 2 =

r3 , 3 r2

Magnitudes of friction forces are generally small. So, if we want to transmit larger amounts of forces, friction becomes inadequate and slip occurs. To prevent slip, we make the joint between links 2 and 3 form closed. This is obtained by putting teeth around the periphery of the gear blanks. For fitting these details, we need some space. We simply separate the gear blanks apart a bit. This separation causes the transmitted force to at an angle called pressure angle, denoted by . Pressure angle is standardized; In imperial system

= 20 o = 18.5 o

In international system

3 I13 r3
Pitch Circle

r2 2 1

FG

v Gear forces FG can be separated into two components Ft , tangential force in tangent

direction and Fr , radial force in the direction of radius.

3 r2 2 1 Ft
FG

Fr Fr
FG

I13 Ft

r3
Pitch Circle

For kinematic considerations the relative size of the teeth with respect to the blank is important. Characteristic dimension for the blank is either the diameter or circumference of the pitch circle. Characteristic dimension for the tooth is either the number of teeth on the blank or the length of the portion of the pitch circle within the tooth body.

Diametral pitch Pd = Circular pitch Pc =

# teeth Pitch circle diameter

* Pitch circular diameter

# teeth

and Pc =

Pd

These two are used to Imperial System. In European, International, German and Turkish standards:
Module = Pitch circle diameter (mm) # teeth

Module and Diametral pitch number are standardized.

Helical Gears

To improve the force carrying capacity of the gears the teeth are cut in a helix. This increase the tooth thickness, so helical gears are stronger. Also they operate with less noise. Force acting normal to the tooth surface, hence it makes an angle of axis of rotation and with the common tangent. (helix angle) with the gear

Fr FG Fa Ft

Ft

Fa
gear axis of rotation

Fr FG Fa

The following relations are evident from figure:

v v v v FG = Fa + Fr + Ft

Ft

Fa = Ft tan Fr = Ft tan

Bevel gears

Bevel gears are conical in shape and used to couple the shafts not parallel but intersecting. Point of intersection of shafts is called the apex. Gear force acts as distributed over the whole tooth thickness, but we can assume a resultant single force acting on the mid point of the tooth thickness.

resultant force acts at the mid point of the gear thikchness

Example: The gear train shown in the figure is

composed of 6 diametral pitch spur gears and 20 degrees pressure angle. Link 2 is the driving gear, delivering 25 Hp at a CCW speed of 900 rpm. Gear 3 is an idler and gear 4 carries the external load. Draw freebody diagrams of the gears, show all the forces acting and calculate their magnitudes.

18 T 2 3

20 T 36 T

Solution: Given: = 20 o
Diametral pitch = 6 Power = 25 Hp

F2y 18 T F2x 2 y x F'3t F4x 4

4 2

F2t

F2r F'3r 3 F3x F3t F3y 36 T

F4r F4t

F3r

F4y 20 T

From second gear freebody diagram:

F F

= 0 ; F2 x F2t = 0 F2 x = F2t = 0 ; F2 r F2 y = 0 F2 y = F2 r

(1) (2)

M F F M F F M
x

= 0 ; 2 F2t * r2 = 0 2 = F2t * r2

(3)

From third gear freebody diagram: = 0 ; F3 x + F3r + F2t = 0 F3 x = F3r + F2t = 0 ; F3 y F2 r F4t = 0 F3 y = F2 r + F4t
3

(4) (5) (6)

= 0 ; 3 F3t * r3 + F2t * r3 = 0 3 = F3t * r3 F2t * r3 2

From fourth gear freebody diagram:

x

= 0 ; F4 x F4t = 0 F4 x = F4t
= 0 ; F4 r + F4t = 0 F4 y = F4 r
4

(7) (8) (9)

= 0 ; 4 + F4t * r4 = 0 42 = F4t * r2

Radius of the gears can be calculated following formulas:

Diametral pitch Pd = d2 =

# teeth # teeth Pitch circle diameter d 2 = Pitch circle diameter Pd

# teeth # teeth 18 r2 = r2 = = 1,5" Pd 2 * P2 2*6

r3 = r4 =

# teeth 36 r3 = = 3" 2 * P3 2*6 # teeth 20 r4 = = 1,67" 2 * P4 2*6

Gear forces of the second gear become:

F2t = 33000 * Power * 12 33000 * 25 * 12 = = 1167,14 lb 2 * * n 2 * r2 2 * * 900 *1,5

F2 r = F2t * tan F2 r = 1167,14 * tan 20 = 424,8 lb

Speed of the fourth gear is:

n4 = T3 * T2 36 * 18 * n2 = * 900 = 810 rpm T2 * T4 20 * 36

Then, gear forces of the fourth gear become:

F4t = 33000 * Power * 12 33000 * 25 * 12 = = 1168,3 lb 2 * * n 4 * r4 2 * * 810 * 1,67

F4 r = F4t * tan F4 r = 1168,3 * tan 20 = 425,22 lb

Using the equations (1,2,3,4,5,6,7,8,9) unknowns become: F2 x = 1167,14 lb

F2 y = 424,8 lb

2 = 1750,7 lb.in
F3 x = 1501,23 lb
F3 y = 1370,18 lb

3 = 0 lb.in
F4 x = 425,22 lb F4 y = 1168,3 lb

4 = 1946,97 lb.in

Example:

Consider

the

gear

train

composed of spur gears. Shaft 2 is the input of the train, and it delivers 6 hp at a speed of 600 rpm CCW when viewed from bottom. Calculate the bearing forces at C and D. Pressure angle is = 20 o .

B 1"

Solution: Given: = 20 o
Diametral pitch = 6 Power = 25 Hp n 2 = 600 rpm

12 P, 36 T C

12 T
2

1" X A

Top view of the assembly is given below.

Freebody diagram of the gears are given below.

FDz D F3t x F3r

y FDx
F2r FAz F2t A FAx

FBz B x

z FBx

FCz FCx

Radius of the gears can be calculated from the definition of diametral pitch;
Diametral pitch Pd = d2 =
# teeth # teeth Pitch circle diameter d = Pitch circle diameter Pd

# teeth # teeth 12 r2 = r2 = = 0,5" Pd 2 * P2 2 * 12

r3 =

# teeth 36 r3 = = 1,5" 2 * P3 2 * 12

Gear forces become:

F2t =

33000 * Power * 12 33000 * 6 * 12 = = 1260,5 lb 2 * * n 2 * r2 2 * * 600 * 0,5

F2 r = F2t * tan F2 r = 1260,5 * tan 20 = 458,79 lb F3t = F2t = 1260,5 lb F3r = F2 r = 458,79 lb

3 = F3t * r2 = 1260,5 *1,5 = 1890,70 lb.in CCW

The shaft 3 is in static equilibrium with the gear forces, bearing forces and the torques. All the forces and all the moments acting should add up to zero. Forces and moments act in 3 dimensional space, so, overall calculations may be difficult. If a body is static, it is seen static in all directions.

z C FCz
Using the y-z plane view,

1260,5 lb D

y
C

FCz

458,79 lb

FDz y D

FDz

F F

=0 = 0 ; FCz + FDz F3t = 0 FCz + FDz = 1260,5 lb

C

(2)

= 0 ; F3t * 1"+ FDz * 2" = 0 FDz =

F3t * 1" = 630,25 lb 2"

FCz + FDz = 1260,5 lb FCz = 1260,5 630,25 = 630,25 lb Using the x-y plane view,

F F

= 0 ; FCx + FDx F3r = 0 FCx + FDx = 458,79 lb =0 (3)

F3r * 1" = 229,395 lb 2"

= 0 ; F3r * 1" FDx * 2" = 0 FDx =

FCx + FDx = 458,79 lb FCx = 458,79 229,395 = 229,395 lb

2 2 FC = FCx + FCz = 229,3952 + 630,252 = 670,7 lb70o 2 2 FD = FDx + FCx = 229,3952 + 630,252 = 670,7 lb70o

Example: Gear 2 is rotating CCW at 1000 rpm, actuated by a 5 Hp electric motor. The gears

are all of helical type with 20 degrees of pressure angle and 30 degrees of helical angle, whose teeth numbers and pitch are shown in the figure. Calculate the gear forces and their components and draw freebody diagram of each gear with all the force components, showing the bearing forces and external loads.

3 2

4 y x

20 T, 5 P 40 T

15 T

x z
Solution: Given: = 20 o , = 20 o
Diametral pitch = 5 , Power = 5 Hp

n2 = 1000 rpm Gear forces come from power. For second gear;
r2 = # teeth 20 r2 = = 2" 2* P 2*5 33000 * Power * 12 33000 * 5 * 12 = = 157,56 lb 2 * * n2 * r2 2 * * 1000 * 2

F2t =

F2 r = F2t * tan F2 r = 157,56 * tan 20 = 57,35 lb F2 r = F2t * tan F2 r = 157,56 * tan 30 = 90,97 lb For third gear;

n3 = r3 =

T2 20 * n2 = * 1000 = 500 rpm T3 40 # teeth 40 r3 = = 4" 2* P 2*5 33000 * Power * 12 33000 * 5 * 12 = = 157,56 lb 2 * * n3 * r3 2 * * 500 * 4

F ' 3t =

F '3r = F '3t * tan F '3r = 157,56 * tan 20 = 57,35 lb F '3r = F '3t * tan F ' 3r = 157,56 * tan 30 = 90,97 lb

F2t F2r F2a z F3r=F2r F3a=F2a F 3t=F2t F'3a F'3t F'3r

F'3t=F4t F'3r=F4r F'3a=F4a

From second gear freebody diagram:

y2
F2y F2x z F2z 2 F2a

z2

F2t F2r x

F = 0; F F = 0; F F = 0; F M = 0 ;
x y z z

2x

F2 r = 0 F2 x = F2 r F2t = 0 F2 y = F2t F2 a = 0 F2 z = F2 a F2t * r2 = 0 2

2y

2z 2z

2 z = F2t * r

= 0 ; 2 y F2 a * r2 = 0 2 y = F2 a * r2

From the above equations second gear bearing forces and torques become: F2 x = 57,35 lb, F2 y = 157,56 lb, F2 z = 90,97 lb

2 y = 181,94 lb.in along y 2 z = 315,12 lb.in along + z

From third gear freebody diagram:

y F3r=F2r F3a=F2a F3t=F2t z F3x F3z F'3r 3 F'3a x F3y

y3 z3
F'3t

= 0 ; F3 x F ' 3r + F2 r = 0 F3 x = F ' 3r F2 r
3t 3y 3t 3y 3t 3t

F = 0 ; F F + F ' = 0 F =F + F ' F = 0; F + F + F = 0 F = F + F M = 0 ; F * r + F ' *r = 0 = F * r F ' *r M = 0 ; + F * r F ' *r = 0 = F * r + F ' *r

y z 3z 3a 2a 3z 3a 2a z 3z 2t 3 3t 3 3z 2t 3 3t 3 y 3y 2a 3 3a 3 3y 2a 3 3a

From the above equations and third gear bearing forces and torques become: F3 x = 0 lb, F3 y = 315,12 lb, F3 z = 181,94 lb

3y = 0 3z = 0
From fourth gear freebody diagram:

y F'3t=F4t F'3r=F4r F'3a=F4a z F4x F4z 4

y4
F4y

z4
x

F = 0; F + F ' = 0 F = F ' F = 0; F F ' = 0 F = F ' F = 0; F F ' = 0 F = F' M = 0 ; + F ' *r = 0

x 4x 3r 4x y 4y 3t 4y 3t z 4z 3a 4z 3a z 4z 3t 4

3r

4 z = F ' 3t *r4

= 0 ; 4 y F '3a *r4 = 0 4 y = F ' 3a *r4

From the above equations fourth gear bearing forces and torques become: F4 x = 57,35 lb, F4 y = 157,56 lb, F4 z = 90,97 lb

4 y = 136,45 lb.in along + y 4 z = 236,34 lb.in along z

Example: In the figure a simple gear train is

shown, composed of two 10 pitch straight bevel gears, larger gear having 50 and smaller 20 teeth, placed to couple two intersecting shafts at right angles to each other. Gear 1, rotating CW when viewed from left is driving gear 2 by delivering it 5 HP at 1000 rpm. The blank thickness of the smaller gear is 1 inch. Calculate the forces that bearings at A and B carry, if all the axial force is carried by the bearing at A. Pressure angle is = 20 o .

1000 rpm

1 2

11 1"

4"

Solution: Given: = 20 o
Diametral pitch = 10 Power = 5 Hp n1 = 1000 rpm

0.5"

Half cone angle of the first gear;

= tan 1
r1 = r2 =

2.5 = 68 0.2' 1

# teeth 50 r1 = = 2,5" 2 * P1 2 * 10 # teeth 20 r2 = = 1" 2 * P2 2 * 10

rav1 = r1 0.5" = 2,5 0,5 = 2"

Forces on the first bevel gear

F1t = 33000 * Power *12 33000 * 5 * 12 = = 157,56 lb 2 * * n1 * r1 2 * * 1000 * 2,0

F1r = F1t * tan * sin F1r = 157,56 * tan 20 * sin 68,2 = 53,25 lb F1r = F1t * tan * cos F1r = 157,56 * tan 20 * cos 68,2 = 21,256 lb

Freebody diagram of the gears are given below.

x Ft1 z Fr1 Fr2=Fa1 Fa1 FAz A FAy FAx Fa2=Fr1 Ft2=Ft1

2
FBz
Using the plane views of the second gear,

FBx B

y + 21,257 lb 53,25 lb FAx FAy 4" FBx FBz 1,5" 157,54 lb x z

21,257 lb 1,5" FAz FAy 4"

F F

= 0 ; 53,25 + FBz FAz = 0 = 0; FAy 21,257 = 0

M B = 0 ; FAx * 4"+21,257 * 0,8 53,25 * 5,5 = 0

F = 0 ;157,54 + F F = 0 F = 0; F 21,257 = 0 M = 0 ; F * 4"157,56 * 5,5 = 0

z Az Bz y Ay B Az

FAz = 68,913 lb FAy = 21,257 lb FBz = 15,66 lb r r r r FA = 68,913 i + 21,257 j + 216,645 k lb r r r FA = 15,66 i 59,085 k lb

FAz = 216,645 lb FBz = 59,085 lb

Example: Gear 2 is rotating CCW at 1000 rpm, actuated by a 20 HP electric motor. It is delivering half of its power to gear 3 and other half to gear 4, whose teeth numbers and pitches are as shown in the figure. The gears are all of spur type with 20 degrees of pressure angle. Calculate the gear forces and their components, determine their directions and draw free body diagram of each gear with all the force components, showing the bearing forces and external loads. Assume that the gears thickness is negligible. Solution:

20 T, 5 P 3 2

4 30 T, 5 P 40 T

25 T

Given: = 20 , Diametral pitch = 5 ,

Power = 20 Hp

F3y 20 T F3x 3 y F 23t x F32t F24t F4x 4

4 2 3

F23r F32r 2 F2x

F24r

F42r

F42t
r r'

F4y 30 T

F2y 25 T 40 T

r =

# teeth 2* P

r =

40 = 4" 2* 5

r' = r3 = r4 =

# teeth 25 r' = = 2 .5" 2* P 2* 5 # teeth 20 r3 = = 2" 2* P 2* 5 # teeth 30 r4 = = 3" 2* P 2* 5

Gear forces of the second gear become:

F32 t =

33000 * Power / 2 * 12 33000 * 10 * 12 = = 157 .56 lb 2 * * n2 * r 2 * * 1000 * 4

F32 r = F32 t * tan F32 r = 157 .56 * tan 20 = 57 .35 lb

F42 t = 33000 * Power / 2 * 12 33000 * 10 * 12 = = 252 .10 lb 2 * * n2 * r' 2 * * 1000 * 2 .5

F42 r = F42 t * tan F42 r = 252 .10 * tan 20 = 91 .76 lb

From the third gear freebody diagram: F23 t = F32 t = 157 .65 lb F23 r = F32 r = 57 .35 lb

F F M

= 0 ; F3 x + F23 t = 0 F3 x = F23 t = 157 .65 lb = 0 ; F3 r F23 y = 0 F3 y = F23 r = 57 .35 lb

3

(1) (2) (3)

= 0 ; 3 F23 t * r3 = 0 3 = F23 t * r3 = 157 .56 * 2 = 315 .12 lb.in CCW

From second gear freebody diagram:

F F M

= 0 ; F2 x + F32 t + F42 r = 0 F2 x = F32 t + F42 r = 249 .32 lb = 0 ; F2 y F32 r + F42 t = 0 F2 y = F32 r + F42 t = 194 .75 lb
2

(4) (5)

= 0 ; 2 F32 t * r F42 t * r' = 0 3 = F32 t * r + F42 t * r' = 1260 .49 lb.in CCW (6)

From fourth gear freebody diagram: F24 t = F42 t = 252 .10 lb

F 2 r = F 32 r = 57 . 35 lb

F F M

= 0 ; F4 x F24 r = 0 F4 x = F24 r = 91 .76 lb = 0 ; F4 y F24 t = 0 F4 y = F4 t = 252 .10 lb

4

(7) (8) (9)

= 0 ; 4 F24 t * r4 = 0 4 = F24 t * r4 = 756 .3 lb.in CCW

Example: Gear 3 is rotating CCW at 1000 rpm, actuated by a 20 HP electric motor. The gears are all of spur type with 20 degrees of pressure angle. Calculate the gear forces and their components, determine their directions and draw free body diagram of each gear with all the force components, showing the bearing forces and external loads. Assume that the gears thickness is negligible.

20 T, 5 P 3 2

4 30 T, 5 P
Given: = 20 o , Diametral pitch = 5 , Power = 20 Hp

25 T 40 T

F3y 20 T F3x 3 y x F32t

2 3

F 23t F23r F32r 2 F2x

F4x 4

F24r F24t

F42r
r r'

F4y 30 T

F 42t

F2y 25 T 40 T

r =

# teeth 2* P

r =

40 = 4" 2* 5

r' = r3 = r4 =

# teeth 25 r' = = 2 .5" 2* P 2* 5 # teeth 20 r3 = = 2" 2* P 2* 5 # teeth 30 r4 = = 3" 2* P 2* 5

Gear forces of the second gear become:

F23 t = 33000 * Power * 12 33000 * 20 * 12 = = 630 .25 lb 2 * * n3 * r3 2 * * 1000 * 2

F32 r = F32 t * tan F32 r = 630 .25 * tan 20 = 229 .4 lb

F42 t = 33000 * Power * 12 33000 * 20 * 12 = = 1008 .4 lb 2 * * n2 * r' 2 * * 500 * 2 .5

F42 r = F42 t * tan F42 r = 1008 .4 * tan 20 = 367 lb From the third gear freebody diagram: F23 t = F32 t = 630 .25 lb F23 r = F32 r = 229 .4 lb

F F

= 0 ; F3 x F23 t = 0 F3 x = F23 t = 630 .25 lb = 0 ; F23 r F3 y = 0 F3 y = F23 r = 229 .4 lb (2)

(1)

M F F M
x

= 0 ; 3 F23 t * r3 = 0 3 = F23 t * r3 = 630 .25 * 2 = 1260 .5 lb.in CCW

(3)

From second gear freebody diagram: = 0 ; F2 x + F32 t + F42 r = 0 F2 x = F32 t + F42 r = 997 .25 lb = 0 ; F2 y F32 r F42 t = 0 F2 y = F32 r + F42 t = 1237 .8 lb
2

(4) (5) (6)

= 0 ; 2 F32 t * r + F42 t * r' = 0 3 = F32 t * r F42 t * r' = 0 lb.in

From fourth gear freebody diagram: F24 t = F42 t = 1008 .4 lb

F24 r = F42 r = 367 lb

F F M

= 0 ; F4 x F24 r = 0 F4 x = F24 r = 367 lb = 0 ; F4 y + F24 t = 0 F4 y = F4 t = 1008 .4 lb

4

(7) (8) (9)

= 0 ; 4 + F24 t * r4 = 0 4 = F24 t * r4 = 3025 .2 lb.in CW