MODULE IV

ARUN JOSE TOM, MLMCE, BME 1

Automobiles and Power Transmission
Devices
ARUN JOSE TOM, MLMCE, BME 2
 TYPES OF AUTOMOBILES

Purpose
• a) Passenger Vehicle: Carries passengers. Eg. Car, jeep, bus
• b) Goods Vehicle: Vehicles that carries goods. Eg. Truck
Capacity
• a) Light Motor Vehicle: Carry light things, less in size and weight.
Gross vehicle weight does not exceed 7500kg. Eg. Car, motor cycle,
scooter
• b) Heavy Motor Vehicle: Can carry very heavy materials and possess
large mass. Gross vehicle weight exceeds 12000kg. Eg. Bus, lorry
Fuel Used
• a) Petrol Vehicles: Car, scooter
• b) Diesel Vehicles: jeep, truck, bus
• c) Electric Vehicle: electric car, electric buses

ARUN JOSE TOM, MLMCE, BME 3

• d)Gas Vehicles: CNG vehicles

Based on type of transmission

• a) Automatic Transmission Vehicle: capable of changing gear
automatically
• b) Manual Transmission Vehicle: gear have to be changed manually
• c) Semi-Automatic Transmission Vehicles: manual and automatic
mode, gear changes without a clutch pedal

Drive of the vehicle

• a) Rear Wheel Drive: rear wheels are driven by the engine
• b) Front Wheel Drive: front wheels are driven by the engine
• c) All Wheel Drive: all the wheels are driven by the engine

ARUN JOSE TOM, MLMCE, BME 4

Major Components of an Automobile

ARUN JOSE TOM, MLMCE, BME 5

ARUN JOSE TOM, MLMCE, BME 6
• Power transmitted from engine to flywheel through
crankshaft

• When clutch is in engaged position, power transmitted

from flywheel to gear box through clutch

• From gear box, the power is transmitted to the wheels via

propeller shaft, differential and axle

ARUN JOSE TOM, MLMCE, BME 7

Clutch Engaged

PROPELLER
ENGINE → GEAR BOX → SHAFT
→ DIFFERENTIAL

WHEELS AXLE
←

ARUN JOSE TOM, MLMCE, BME 8

Clutch Disengaged

ENGINE FLYWHEEL
→ → NO POWER TRANSFER
HEELS

No power is transmitted to clutch

Engine is isolated from the wheels

ARUN JOSE TOM, MLMCE, BME 9

• Engine and flywheel is connected by a shaft called
crank shaft( driver shaft)

• Clutch and gear box is connected by a shaft( driven

shaft)

ARUN JOSE TOM, MLMCE, BME 10

ARUN JOSE TOM, MLMCE, BME 11
Functions of Major Components of an Automobile

Chassis and Frame

It supports the engine, body, braking system, transmission

system, steering, passengers…etc

ARUN JOSE TOM, MLMCE, BME 12

Chassis

ARUN JOSE TOM, MLMCE, BME 13

ARUN JOSE TOM, MLMCE, BME 14
 Frame

ARUN JOSE TOM, MLMCE, BME 15

FLYWHEEL

ARUN JOSE TOM, MLMCE, BME 16

ARUN JOSE TOM, MLMCE, BME 17
The main function of a flywheel is to smoothen
out variations in the speed of a crankshaft

ARUN JOSE TOM, MLMCE, BME 18

 GEAR
BOX

PROPELLER CLUTCH
SHAFT
TRANSMISSION
SYSTEM

AXLE DIFFERENTIAL

ARUN JOSE TOM, MLMCE, BME 19

 Transmission System

The power developed by the engine is transferred to the wheels

by transmission system

It consists of
• Clutch
• Gear box
• Propeller Shaft
• Axle
• Differential

ARUN JOSE TOM, MLMCE, BME 20

 TRANSMISSION SYSTEM- Clutch

• Purpose of the clutch is to allow the driver to couple or

decouple the engine and transmission

• Clutch is used to engage or disengage the engine to the gear

box

• When clutch is in engaged position, the engine power flows to

the gear box through clutch and from gear box power flows
to the wheels

ARUN JOSE TOM, MLMCE, BME 21

• When clutch is in disengaged position, the engine power does
not reach to gear box

• When gears are to be changed while vehicle is running, the

clutch permits temporary decoupling of engine and wheels
so that gears can be shifted

• Engine and flywheel is connected by a shaft called crank shaft

( driver shaft)

• Clutch and gear box is connected by a shaft( driven shaft)

ARUN JOSE TOM, MLMCE, BME 22

ARUN JOSE TOM, MLMCE, BME 23
 CLUTCH PLATE
ARUN JOSE TOM, MLMCE, BME 24
 SQUARE JAW
POSITIVE
SPIRAL JAW

CLUTCH
CENTRIFUGAL

FRICTION CONE
MULTIPLE
PLATE
PLATE
SINGLE PLATE

ARUN JOSE TOM, MLMCE, BME 25

ARUN JOSE TOM, MLMCE, BME 26
 MAIN PARTS OF A CLUTCH
It consists of

(a) a driving member,

(b) a driven member, and
(c) an operating member

•Driving member has a flywheel which is mounted on the engine

crankshaft.

• The driven member is a disc called clutch plate. This plate can slide freely
to and fro on the clutch shaft.

• The operating member consists of a pedal or lever which can be pressed to

disengaged the driving and driven plate.

ARUN JOSE TOM, MLMCE, BME 27

1) Positive Clutch

In the engaged position,

the shafts are rigidly
connected and in the
disengaged position, the
shafts will be
disconnected fully

ARUN JOSE TOM, MLMCE, BME 28

ARUN JOSE TOM, MLMCE, BME 29
TYPES OF POSITIVE CLUTCH

ARUN JOSE TOM, MLMCE, BME 30

 2) Friction Clutch

• Basic principle: It operates on the principle of friction. When

two surfaces are brought in contact and are held against each
other due to friction between them, they can be used to
transmit power. If one is rotated, then other also rotates. One
surface is connected to engine and other to the transmission
system of automobile. Thus, clutch is nothing but a
combination of two friction surfaces
• Engagement occurs gradually and hence smooth engagement
is possible
• Working of clutch is based on frictional force, that is, when
two frictional surfaces are brought in contact and pressed,
they are united and rotate together as a single unit

ARUN JOSE TOM, MLMCE, BME 31

SINGLE PLATE CONE
CLUTCH CLUTCH

FRICTION
CLUTCH

ARUN JOSE TOM, MLMCE, BME 32

 A) Single Plate Clutch

• Single plate with friction surface is connected to a driven

shaft

• Driven shaft transfer power to gear box

• Flywheel is connected to the driver shaft( crank shaft)

• Both the shafts are co-axial

ARUN JOSE TOM, MLMCE, BME 33

• During disengagement, a lever keeps the driven
disk(clutch) away from the driving disk(flywheel)

• To engage the clutch, the lever is gradually released

• The spring provides the required axial force to press the

driven disk against the driver disk

• Clutch is nothing but a combination of two friction surfaces

ARUN JOSE TOM, MLMCE, BME 34

ARUN JOSE TOM, MLMCE, BME 35
ARUN JOSE TOM, MLMCE, BME 36
ARUN JOSE TOM, MLMCE, BME 37
 CLUTCH PLATE
ARUN JOSE TOM, MLMCE, BME 38
ARUN JOSE TOM, MLMCE, BME 39
 B) Cone Clutch

• Inner and outer cone as two working surfaces

• Outer cone is fixed to the driving shaft

• Inner cone is free to slide axially on the driven shaft

• Spring provides the necessary axial force to the inner cone to

press against the outer cone, thus engaging the clutch

• Lever is used to disengage the clutch

• Inner cone surface is lined with friction material

• Greater torque transmitting capacity

ARUN JOSE TOM, MLMCE, BME 40

ARUN JOSE TOM, MLMCE, BME 41
ARUN JOSE TOM, MLMCE, BME 42
ARUN JOSE TOM, MLMCE, BME 43
 Transmission System – Gear Box

• It contains gearing arrangement to get different speeds

• Both mating gears have same number of teeth, both will

rotate at same speed

• One gear has less teeth than other, the gear with less
number of teeth will rotate faster than larger gear

• Gear box is used to vary the speed of the propeller shaft

ARUN JOSE TOM, MLMCE, BME 44

 Gears
ARUN JOSE TOM, MLMCE, BME 45
ARUN JOSE TOM, MLMCE, BME 46
ARUN JOSE TOM, MLMCE, BME 47
ARUN JOSE TOM, MLMCE, BME 48
• From the diagram, the main shaft and crankshaft have the
same speed

• Speed of the propeller shaft and main shaft have to be

varied using a gear box

• Low speed of the propeller shaft means higher torque

• High speed of the propeller shaft means less torque

ARUN JOSE TOM, MLMCE, BME 49

ARUN JOSE TOM, MLMCE, BME 50
• From the diagram shown in the previous slide, assume
GEAR D is the driver

• GEAR D have higher speed and GEAR A have lower speed,

It means that shaft connected to GEAR A have higher
torque

• Reverse case, gear A is the driver

• Then GEAR D have the higher speed, so shaft connected to

the GEAR D have low torque and high speed(speed means
RPM, RPM- rotations per minute)

ARUN JOSE TOM, MLMCE, BME 51

 Transmission System – Propeller Shaft

Used to transfer power from gear box to differential

ARUN JOSE TOM, MLMCE, BME 52

ARUN JOSE TOM, MLMCE, BME 53
 Transmission System – Differential

• To distribute power from the propeller shaft to two axles

• Finally the power from the differential is transmitted to

wheel via axles

• Main function of the differential is to give separate amount

of power to each wheels

ARUN JOSE TOM, MLMCE, BME 54

ARUN JOSE TOM, MLMCE, BME 55
 Function of differential

ARUN JOSE TOM, MLMCE, BME 56

 Function of differential

ARUN JOSE TOM, MLMCE, BME 57

ARUN JOSE TOM, MLMCE, BME 58
 Transmission System – Axle

Used to transmit power from differential to wheels

ARUN JOSE TOM, MLMCE, BME 59

ARUN JOSE TOM, MLMCE, BME 60
 Steering System

• Front wheels can be turned to left and right by steering

system

• It also provides stability to vehicle

• Nowadays hydraulic and power steering systems are used

to turn the wheels

ARUN JOSE TOM, MLMCE, BME 61

ARUN JOSE TOM, MLMCE, BME 62
 Suspension System

• Main goals: comfort – contact - control

• It separates the wheel and axle assembly of the

automobile from its body

• Main function of the suspension system is to isolate the

body of the vehicle from shocks and vibrations
generated due to irregularities on the surface of roads

ARUN JOSE TOM, MLMCE, BME 63

Coil spring suspension

ARUN JOSE TOM, MLMCE, BME 64

Leaf spring
suspension

ARUN JOSE TOM, MLMCE, BME 65

Coil spring suspension

ARUN JOSE TOM, MLMCE, BME 66

 Braking System

• It is used to slow down or stop the vehicle

• Brakes commonly use friction between two surfaces

pressed together to convert the kinetic energy of the
moving object into heat

• In brake, there is engagement of moving member to a

stationary member

ARUN JOSE TOM, MLMCE, BME 67

• Mainly two types a) Drum Brake b) Disk Brake

• In drum and disk brake, a fixed shoe rubs against a

moving drum or disc

• Friction material is attached to the fixed part

ARUN JOSE TOM, MLMCE, BME 68

DRUM DISK
BRAKE BRAKE

BRAKES

ARUN JOSE TOM, MLMCE, BME 69

Mechanical Hydraulic
Type Type

Drum Brake

ARUN JOSE TOM, MLMCE, BME 70

 Drum Brake

• Commonly used in light vehicles

• It consists of two shoes

• Outer surface of the shoes are lined with some friction

material

• Each shoe is pivoted at the bottom end

ARUN JOSE TOM, MLMCE, BME 71

ARUN JOSE TOM, MLMCE, BME 72
 A) Mechanical Drum Brake

• Each shoe is pivoted at the bottom end

• Top end of the shoes are contact with a cam

• When the brake is pressed, cam rotates and the shoes are
pushed outwards against the rotating drum

• Rotating drum is fixed to the wheel

• Friction between the shoes and the drum causes an

reduction in drum speed

ARUN JOSE TOM, MLMCE, BME 73

ARUN JOSE TOM, MLMCE, BME 74
ARUN JOSE TOM, MLMCE, BME 75
 B) Hydraulic Drum Brake

• Each shoe is pivoted at the bottom end

• Other end of the shoes are contact with a PISTON

Arrangement

• When the brake is pressed, piston moves outward and the

shoes are pushed outwards against the rotating drum

• Rotating drum is fixed to the wheel

• Friction between the shoes and the drum causes an

reduction in drum speed
ARUN JOSE TOM, MLMCE, BME 76
ARUN JOSE TOM, MLMCE, BME 77
ARUN JOSE TOM, MLMCE, BME 78
ARUN JOSE TOM, MLMCE, BME 79
FLOATING
DISC FIXED
TYPE BRAKE TYPE

ARUN JOSE TOM, MLMCE, BME 80

DISC BRAKE- floating type

ARUN JOSE TOM, MLMCE, BME 81

• The main components are brake pads, caliper and the rotor
• Brake pads are the rough friction surface that is pressed
against the rotor to stop the wheel
• Rotor is a round plate attached to the hub
• Hub is attached to the wheel
• Piston presses one brake pad against the rotor, while the
caliper presses the other(floating type)
• As the brake fluid pressure in the cylinder increases, piston
moves to left, piston also pushes the caliper to the right.
This allows both brake pads to press against the wheel
simultaneously

ARUN JOSE TOM, MLMCE, BME 82

ARUN JOSE TOM, MLMCE, BME 83
ARUN JOSE TOM, MLMCE, BME 84
ARUN JOSE TOM, MLMCE, BME 85
 DISC BRAKE- fixed type

• The main components are brake pads, caliper and the rotor

• Brake pads are the rough friction surface that is pressed

against the rotor to stop the wheel

• Rotor is a round plate attached to the hub

• Hub is attached to the wheel

• Both Piston presses the brake pads against the rotor due to
increase in the fluid pressure inside the cylinder

ARUN JOSE TOM, MLMCE, BME 86

ARUN JOSE TOM, MLMCE, BME 87
ARUN JOSE TOM, MLMCE, BME 88
 Methods of Power Transmission

• Mechanical power can be transmitted from one shaft to

another by following methods
• Belt drive
• Rope drive
• Chain drive
• Gear drive

• The shaft from which power is transmitted is called driver

shaft and the shaft to which power is transmitted is called
driven shaft

ARUN JOSE TOM, MLMCE, BME 89

The choice of the type of drive for power transmission
depend on many factors such as

• Distance between shafts

• Amount of power to be transmitted

• Speed ratio of shafts

• Accuracy required

ARUN JOSE TOM, MLMCE, BME 90

 BELT DRIVE

• A belt is a thin inextensible band made of leather, rubber,

steel, canvas or balata
• Belts are used to transmit power between two parallel
shafts, which are at a considerable distance apart
• Belts are made endless to run over the pulleys mounted on
the shafts
• Friction between the belt and the pulley is responsible for
transmitting power from one pulley to other
• It’s a friction drive

ARUN JOSE TOM, MLMCE, BME 91

• It is not a positive drive, since there is always some
possibility of slipping between the belt and pulley

Amount of power transmitted depends on

• Velocity of the belt

• The tension with which the belt is placed under the pulleys

• The arc of contact between the belt and the smaller pulley

ARUN JOSE TOM, MLMCE, BME 92

ARUN JOSE TOM, MLMCE, BME 93
FLAT BELT V BELT

TYPES OF
BELTS

ARUN JOSE TOM, MLMCE, BME 94

a) Flat Belt

ARUN JOSE TOM, MLMCE, BME 95

FLAT BELT DRIVE
ARUN JOSE TOM, MLMCE, BME 96
FLAT BELT
PULLEYS

ARUN JOSE TOM, MLMCE, BME 97

• Flat belt are run on flat pulleys
• They are used in sawmills, conveyors, electrical
generators…etc
• Used for moderate amount of power transfer
Advantages
• Simple in construction, smooth operation, low maintenance
and long life
• Flexible
Disadvantages
• Not positive drives
• Less efficient
• Not suitable for short distances

ARUN JOSE TOM, MLMCE, BME 98

 b) V BELT

• V belts have trapezoidal cross section

• They run in the V- grooved pulleys

• Multiple V belts are used when the power to be

transmitted is large for a single belt

• V belts are used in automotives and in agricultural purposes

ARUN JOSE TOM, MLMCE, BME 99

Advantages
• Transmits higher torque than flat belts
• Suitable for short distance
• Easily installed and removed
• Slip is negligible
• Operation is quiet
• Suitable for large speeds
Disadvantages
• Not suitable for large distances
• Costly
• V belts cannot be repaired
• Construction is complicated
ARUN JOSE TOM, MLMCE, BME 100
Single V belt

ARUN JOSE TOM, MLMCE, BME 101

Single V belt drive
ARUN JOSE TOM, MLMCE, BME 102
 Multiple V belt

ARUN JOSE TOM, MLMCE, BME 103

 Multiple V belt drive
ARUN JOSE TOM, MLMCE, BME 104
V BELT PULLEYS

ARUN JOSE TOM, MLMCE, BME 105

 V Belt Flat Belt
Suitable for shorter distance Suitable for longer distance

Trapezoidal section Rectangular section

Frictional grip is more Frictional grip is less

Power transmitted is more Power transmitted is less

Velocity ratio is high Velocity ratio is low

Occurrence of slip is seldom Slip occurs easily

possible

ARUN JOSE TOM, MLMCE, BME 106

 Compound
Belt Drive
Stepped Or Belt Drive
Cone Pulley With Idler
Drive Pulleys

Open Belt Types of Cross Belt

Drive Belt Drives Drive

ARUN JOSE TOM, MLMCE, BME 107

1.Open Belt Drive

ARUN JOSE TOM, MLMCE, BME 108

ARUN JOSE TOM, MLMCE, BME 109
ARUN JOSE TOM, MLMCE, BME 110
ARUN JOSE TOM, MLMCE, BME 111
• It is used to transmit power when the distance between the
shafts is large

• Both shafts are in parallel

• Both shafts rotates in the same direction

• When the driver rotates in the clockwise direction, the

lower side of the belt is tight and the upper side is slack

• Upper side of the belt is called the slack side

• Lower side of the belt is called the tight side

ARUN JOSE TOM, MLMCE, BME 112

2.Cross Belt Drive

ARUN JOSE TOM, MLMCE, BME 113

ARUN JOSE TOM, MLMCE, BME 114
• Shafts are parallel and rotating in the opposite directions
• At the point where the belt crosses, it rubs against itself and
wears
• The drive should operate at low velocity

ARUN JOSE TOM, MLMCE, BME 115

ARUN JOSE TOM, MLMCE, BME 116
3.Belt Drive With Idler Pulleys

ARUN JOSE TOM, MLMCE, BME 117

• Shafts arranged in parallel and rotating in same direction

• This drive is provided to deliver high velocity

• Idler pulley increases the angle of contact between belt

and shaft

ARUN JOSE TOM, MLMCE, BME 118

ARUN JOSE TOM, MLMCE, BME 119
ARUN JOSE TOM, MLMCE, BME 120
4. Compound Belt Drive

ARUN JOSE TOM, MLMCE, BME 121

It is used when
power is
transmitted
from one shaft
to another
through a
number of
pulleys

ARUN JOSE TOM, MLMCE, BME 122

ARUN JOSE TOM, MLMCE, BME 123
5. Stepped or Cone Pulley Drive

ARUN JOSE TOM, MLMCE, BME 124

ARUN JOSE TOM, MLMCE, BME 125
Used for changing the speed of driven shaft while the driving
shaft is maintained at constant speed

ARUN JOSE TOM, MLMCE, BME 126

ARUN JOSE TOM, MLMCE, BME 127
ARUN JOSE TOM, MLMCE, BME 128
 Stepped or cone pulley

ARUN JOSE TOM, MLMCE, BME 129

 Calculation of length of belt
a) Open Belt Drive

ARUN JOSE TOM, MLMCE, BME 130

• X= distance between centers of pulleys
• r1, r2 = radii of larger and smaller pulleys respectively
• L = total length of belt

L = л(r1+r2) + (r1-r2)2/x + 2x……

α = (r1-r2)/x

ARUN JOSE TOM, MLMCE, BME 131

b) Cross Belt Drive

ARUN JOSE TOM, MLMCE, BME 132

• X= distance between centers of pulleys
• r1, r2 = radii of larger and smaller pulleys respectively
• L = total length of belt

L = л(r1+r2) + (r1+r2)2/x + 2x……

α = (r1+r2)/x

ARUN JOSE TOM, MLMCE, BME 133

Ratio of Belt Tensions

ARUN JOSE TOM, MLMCE, BME 134

• T1 = tight side tension
• T2 = slack side tension
• Ѳ = angle of contact between the belt and pulley in radians
• μ = coefficient of friction between the belt and pulley

T1/T2 = e μ Ѳ

ARUN JOSE TOM, MLMCE, BME 135

 Power Transmitted By Belt Drive

• T1 = tight side tension, N

• T2 = slack side tension, N
• r = radius of pulley, m
• d = diameter of pulley, m
• ω = angular velocity, rad/sec
• V = velocity of belt, m/s
• N = speed of pulley(rotations per minute, rpm)
• If d is the diameter of driver pulley then N should be the
speed of driver pulley and if d is the diameter of driven
pulley then N should be the speed of driven pulley

ARUN JOSE TOM, MLMCE, BME 136

• Torque exerted on the pulley = (T1 - T2)r
• Work done per sec = (T1 - T2)r ω

• Power transmitted = (T1 - T2)V

• V=rω
• ω = 2лN/60

• Power transmitted = [(T1 - T2) лdN]/60, Watts

ARUN JOSE TOM, MLMCE, BME 137

Velocity Ratio of a Belt Drive

ARUN JOSE TOM, MLMCE, BME 138

• Velocity ratio, i = speed of driven shaft / speed of driver shaft

Also, Velocity ratio, i = diameter of driver pulley / diameter of

driven pulley

i = N2/N1 = d1/d2

• N2= speed of driven shaft

• N1 = speed of driver shaft
• d1 = diameter of driver pulley
• d2 = diameter of driven pulley

ARUN JOSE TOM, MLMCE, BME 139

If the thickness of the belt, t is also considered, then

i = N2/N1 = (d1+t)/(d2+t)

ARUN JOSE TOM, MLMCE, BME 140

 Slip of Belt Drive

• Slip is measured as a difference between the linear speeds

of the pulley rim and the belt over it
• Generally it is expressed as a percentage

Slip occurs due to

 Friction between the belt and pulley decreases
 When the smoothness of pulley surface is high
 Difference between tensions in the tight and slack sides are
very large

ARUN JOSE TOM, MLMCE, BME 141

• S1= % slip between the driver pulley and belt
• S2 = % slip between the driven pulley and belt
• d1 = diameter of driver pulley
• d2 = diameter of driven pulley

• S = S1 + S2, S- total slip

1) Effect of total slip on velocity ratio(neglecting the belt

thickness)

i = N2/N1 =

ARUN JOSE TOM, MLMCE, BME 142

2) Effect of total slip on velocity ratio(considering the belt
thickness)

i = N2/N1 =

ARUN JOSE TOM, MLMCE, BME 143

ROPE DRIVE

ARUN JOSE TOM, MLMCE, BME 144

ARUN JOSE TOM, MLMCE, BME 145
ARUN JOSE TOM, MLMCE, BME 146
Ropes

ARUN JOSE TOM, MLMCE, BME 147

• Rope drives are used for transmission of large amount of
power over long distances
• For a rope drive, groove angle of the pulley is usually 45⁰
• Fibre ropes and wire ropes are used

Advantages
• Smooth and silent operation
• Less weight
• Longer life
• Efficiency is high
• More reliable
• Low cost

ARUN JOSE TOM, MLMCE, BME 148

CHAIN DRIVE

ARUN JOSE TOM, MLMCE, BME 149

ARUN JOSE TOM, MLMCE, BME 150
 CHAIN

SPROCKET

ARUN JOSE TOM, MLMCE, BME 151

• Chain drive consists of an endless chain running over
special profile toothed wheels called sprockets

• One of the sprockets will be the driver and the other

driven

• Smaller sprocket is called pinion and the bigger one is

called wheel

ARUN JOSE TOM, MLMCE, BME 152

Advantages
• It is a non-slip drive
• Very high efficiency
• Occupies less space

Disadvantages
• High cost
• More weight
• Needs accurate mountings
• Lubrication is critical

ARUN JOSE TOM, MLMCE, BME 153

ARUN JOSE TOM, MLMCE, BME 154
 SILENT OR
ROLLER CHAIN INVERTED
TOOTH CHAIN
TYPES OF
CHAIN

ARUN JOSE TOM, MLMCE, BME 155

ROLLER CHAIN

ARUN JOSE TOM, MLMCE, BME 156

SILENT/INVERTED TOOTH CHAIN

ARUN JOSE TOM, MLMCE, BME 157

ARUN JOSE TOM, MLMCE, BME 158
GEAR DRIVE

ARUN JOSE TOM, MLMCE, BME 159

• A gear is a toothed wheel
• One gear is mounted on the driving shaft and another one
on the driven shaft, their teeth meshing with each other
• It is a positive drive(no slip)
• The axes of the shafts may be parallel or non-parallel
• When two gears of different sizes mesh, the smaller one is
called pinion and the larger one is called gear
• When pinion(smaller gear) is the driver, output
speed(driver speed) decreases and torque increases
• When the gear(larger gear) is the driver, output
speed(driver speed) increases and torque decreases

ARUN JOSE TOM, MLMCE, BME 160

ARUN JOSE TOM, MLMCE, BME 161
 Double
Bevel
Helical
gears
gears

Helical Worm
gears gears

Spur gears
Types Rack and
of gears pinion

ARUN JOSE TOM, MLMCE, BME 162

1.SPUR GEAR

ARUN JOSE TOM, MLMCE, BME 163

SPUR GEAR DRIVE

ARUN JOSE TOM, MLMCE, BME 164

ARUN JOSE TOM, MLMCE, BME 165
• SPUR gears are those which have teeth cut parallel to the
axis of the shaft

• Spur gears are used to transmit power between parallel

shafts

• They are used in high speed and high load applications

Two types
External gear and internal gear

ARUN JOSE TOM, MLMCE, BME 166

Internal Spur Gear

ARUN JOSE TOM, MLMCE, BME 167

• Internal gears have teeth on the inner periphery

• Two gears rotate in same direction

• Pinion or smaller gear is inside the spur gear

• Internal gears are used in heavy duty tractors, where much

torque is required

ARUN JOSE TOM, MLMCE, BME 168

ARUN JOSE TOM, MLMCE, BME 169
External Spur Gear

ARUN JOSE TOM, MLMCE, BME 170

External gears have teeth on the outer surfaces
and the two shafts rotate in opposite directions

ARUN JOSE TOM, MLMCE, BME 171

2.HELICAL GEAR

ARUN JOSE TOM, MLMCE, BME 172

ARUN JOSE TOM, MLMCE, BME 173
• In helical gear, the teeth cut on the periphery are of helical
screw form
• Helical tooth is inclined at an angle to the axis of the shaft
• Helical gears are used to transmit power between parallel
shafts
• The two shafts rotate in opposite directions
• They have higher load carrying capacity
• They operate smoother and quieter than spur gears

ARUN JOSE TOM, MLMCE, BME 174

3.Herringbone Gear or Double-Helical Gears

ARUN JOSE TOM, MLMCE, BME 175

ARUN JOSE TOM, MLMCE, BME 176
• Herringbone gears have opposing helical teeth which
nullify two axial thrusts
• Load carrying capacity is very high
• These gears are used to transmit power between two
parallel shafts at high speeds
• The two shafts rotate in opposite directions

ARUN JOSE TOM, MLMCE, BME 177

4.BEVEL GEAR

ARUN JOSE TOM, MLMCE, BME 178

STRAIGHT BEVEL GEAR

ARUN JOSE TOM, MLMCE, BME 179

SPIRAL BEVEL GEAR

ARUN JOSE TOM, MLMCE, BME 180

ARUN JOSE TOM, MLMCE, BME 181
• Bevel gears are used to connect two non-parallel shafts
with intersecting axes

• Teeth of these gears are formed on a conical surface

• These gears are used to transmit power between two

shafts at any angle, generally the shafts are at right angles

• They are used to slow speed applications

ARUN JOSE TOM, MLMCE, BME 182

5.WORM GEAR D

ARUN JOSE TOM, MLMCE, BME 183

ARUN JOSE TOM, MLMCE, BME 184
• Worm gears are used for power transmission between
non-intersecting shafts that are generally at right
angles to each other

• Worm gearing consists of worm and worm wheel

• Worm is a threaded screw and is used as the driver

• Worm wheel is a toothed wheel

• Teeth of the worm wheel remain engaged with the

threads of the worm

ARUN JOSE TOM, MLMCE, BME 185

6.RACK AND PINION

ARUN JOSE TOM, MLMCE, BME 186

ARUN JOSE TOM, MLMCE, BME 187
 Rack and pinion gears are used to convert
rotation(pinion) into linear motion(rack) or vice versa

ARUN JOSE TOM, MLMCE, BME 188

Advantages of gear drive
• Smooth and reliable
• Transmits more power

Disadvantages
• Not suitable for large distances
• Needs lubrication
• Maintenance cost is high
• Power loss due to friction
• Production cost is high

ARUN JOSE TOM, MLMCE, BME 189

LAW OF GEARING

ARUN JOSE TOM, MLMCE, BME 190

ARUN JOSE TOM, MLMCE, BME 191
• A gear is a toothed wheel
• One gear is mounted on the driving shaft and another one
on the driven shaft, their teeth meshing with each other
• It is a positive drive(no slip)
• The axes of the shafts may be parallel or non-parallel
• When two gears of different sizes mesh, the smaller one is
called pinion and the larger one is called gear
• When pinion(smaller gear) is the driver, output speed
decreases and torque increases
• When the gear(larger gear) is the driver, output speed
increases and torque decreases

ARUN JOSE TOM, MLMCE, BME 192

GEAR RATIO

• Ratio of the number of teeth on the driven gear to that of

the driver gear
• Z1 = number of teeth on the driver gear
• Z2 = number of teeth on the driven gear

Gear Ratio, G = Z2/ Z1

ARUN JOSE TOM, MLMCE, BME 193

 G increases
• Driven shaft speed decreases
• Driven shaft torque increases

G decreases
• Driven shaft speed increases
• Driven shaft torque decreases

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ARUN JOSE TOM, MLMCE, BME 195
 PLANETARY
GEAR
TRAINS
SIMPLE COMPOUND
GEAR GEAR
TRAINS TRAINS

GEAR
TRAINS

ARUN JOSE TOM, MLMCE, BME 196

 GEAR TRAINS

Combination of gears by means of which motion and

power are transmitted from one shaft to another

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1) Simple Gear Train

ARUN JOSE TOM, MLMCE, BME 198

• Series of gear wheels in which each gear is mounted on a
separate shaft

• Gears in between Driver and Driven gear called idler gears

Fig. A

ARUN JOSE TOM, MLMCE, BME 199

Fig. A shows one driver, one follower and 2 idler gears

Speed ratio = Nfollower/Ndriver = Zdriver/Zfollower

Nfollower = speed of the follower(rpm)

Ndriver = speed of the driver(rpm)
Zfollower = number of teeth on the follower
Zdriver = number of teeth on the driver

ARUN JOSE TOM, MLMCE, BME 200

2) Compound Gear Train

ARUN JOSE TOM, MLMCE, BME 201

ARUN JOSE TOM, MLMCE, BME 202
ARUN JOSE TOM, MLMCE, BME 203
 Fig.B

ARUN JOSE TOM, MLMCE, BME 204

• From Fig.B, gear 1 and gear 4 mounted on separate shafts

• Gear 2 and gear 3 on same shaft, so gear 2 and gear 3 rotate

with equal speed

• Gear 1 is the driver and gear 4 is the follower

Speed ratio = Nfollower/Ndriver = (Zdriver/Z2) X (Z3/Zfollower)

ARUN JOSE TOM, MLMCE, BME 205

Nfollower = speed of the follower(rpm)

Ndriver = speed of the driver(rpm)

Zfollower = number of teeth on the follower

Zdriver = number of teeth on the driver

Z2 = number of teeth on gear 2

Z3 = number of teeth on gear 3

ARUN JOSE TOM, MLMCE, BME 206

3. Planetary Gear Train

ARUN JOSE TOM, MLMCE, BME 207

ARUN JOSE TOM, MLMCE, BME 208
Sun gear or ring gear(DRIVER) Sun gear (DRIVER), Ring
gear is stationary

ARUN JOSE TOM, MLMCE, BME 209

• Planetary gear trains are having one or more gears orbiting
about the central axis of the train

• From the above animation central small gear is called Sun

gear

• Gears over the sun gear called Planet gear

• Outer larger gear called Ring gear

ARUN JOSE TOM, MLMCE, BME 210

GEAR TERMINOLOGY

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ARUN JOSE TOM, MLMCE, BME 212
ARUN JOSE TOM, MLMCE, BME 213
• Pitch Circle: Theoretical or imaginary circle upon which all
the calculations are made
• Pitch Circle Diameter: Diameter of the pitch circle or it is the
mean diameter of the gear wheel. Normally, the size of the
gear is specified by pitch circle diameter
• Pitch Point: Point of contact of two pitch circles
• Addendum Circle: Circle passing through the tips of teeth
• Addendum: Radial distance between pitch circle and
addendum circle
• Dedendum Circle(Root Circle): Circle passing through the
roots of the teeth

ARUN JOSE TOM, MLMCE, BME 214

• Dedendum: Radial distance between pitch circle and dedendum
circle
• Full Depth(Whole Depth) of Teeth:
Full Depth = Addendum+Dedendum

• Top Land: Surface at the top of tooth

• Bottom Land: Surface at the root of the tooth, in between two
adjacent teeth
• Tooth Thickness: Width of the tooth measured along the pitch
circle
• Tooth Space: Width of space between the two adjacent teeth
measured along the pitch circle

ARUN JOSE TOM, MLMCE, BME 215

• Face: Tooth surface between the pitch circle and the top land

• Flank: Tooth surface between the pitch circle and the bottom
land

• Face Width: Length of tooth measured parallel to the axis of

gear

• Profile: Curve formed by the face and flank of the tooth

ARUN JOSE TOM, MLMCE, BME 216

• Backlash: Amount by which the width of a tooth
space(mating gear) exceeds the thickness of the engaging
gear tooth in order to prevent tooth binding under operating
conditions

also backlash is the difference between the tooth space of the

mating gear and the tooth thickness of gear, measured along
the pitch circle

ARUN JOSE TOM, MLMCE, BME 217

• Working Depth: Radial distance between the addendum
circle of a gear and the addendum circle of its mate

• Clearance: Clearance = Whole depth - Working depth

Also clearance is the radial distance between the addendum
circle of a gear and the root circle of its mate

ARUN JOSE TOM, MLMCE, BME 218

• Circular Pitch(Pc): Distance measured along the
circumference of pitch circle from a point from one tooth to
the corresponding point on the adjacent tooth
Pc = (лd)/Z

• Diametral Pitch(P): Number of teeth per unit length of pitch

circle diameter
P = Z/d
• Module(m): Ratio of pitch circle diameter in mm to the
number of teeth
m = d/Z

d=Pitch circle diameter, Z= Number of teeth

ARUN JOSE TOM, MLMCE, BME 219