MD II/PK

06.05.2021
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 GEARS
.....the symbol of motion, symbol of growth

The Symbol of Mechanical

Engineering
A Short Video on Gear Basics...
 WHAT ARE GEARS......

• A friction wheel with teeth cut on it,

i.e. ; a synchronous arrangement of
projections and recesses on a wheel.

projections

recess
⦿ A gear is a rotating machine part having
cut teeth, which mesh with another
toothed part to transmit torque.
⦿ Geared devices can change the
speed, torque, and direction of a
power source.
⦿ The teeth on the two meshing gears all
have the same shape.
⦿ Gears almost always produce a change in
torque, creating a mechanical advantage,
through their gear ratio, and thus may be
considered a simple machine.
TYPES OF GEARS
According to the position of axes of the shafts

a) Parallel
- Spur Gear
- Helical Gear
- Rack andPinion

b)Intersecting
- Bevel Gear

C) Non-intersecting and Non-parallel

- worm and worm gears
 Types of Gears
 Spur gear
 Helical gear
Different
types of gears  Herringbone gear
are :-
 Rack and pinion
 Bevel gear
 Worm and worm gear
SPUR GEAR

⦿ Teeth is parallel
to axis of rotation
⦿ Transmit power
from one shaft to
another parallel
shaft
⦿ Used in Electric
screwdriver,
oscillating sprinkler,
windup alarm clock,
washing machine and
clothes dryer
External Spur Gear
⦿ Inexternal gearing
,the gears of the
two shafts mesh
externally with
each other which is
shown in figure.The
larger of these two
wheels is called
spur wheel or gear
and the smaller
wheel is called
pinion.
Internal Spur Gear
⦿ In internal gearing ,
the gears of these
two shafts mesh
internally with each
other as shown in
figure.

The larger of these

two wheels is
called annular
wheel and smaller
wheel is called
pinion.
HELICAL GEAR

⦿ The teeth on helical gears are

cut at an angle to the face of
the gear.
⦿ This gradual engagement
makes helical gears operate
much more smoothly and
quietly than spur gears .
HELICAL GEAR
 DOUBLE HELICAL
AND HERRINGBONE GEAR
DOUBLE
HELICAL
GEAR
HERRINGBONE
GEAR
 HERRINGBONE GEAR

⦿ A herringbone gear is a specific type

of double helical gear,which is side to
side (not face to face) combination of
two helical gears of opposite hands.

⦿ Herringbone gears are mostly

used on heavy machinery.
 Difference between herringbone gear and
double helical gear
Herringbone Gear Double Helical Gear
In herringbone gear, no gap is In double helical gear, small
provided between two halves. So relief gap is provided between
teeth with left hand helix touches two halves. So teeth with left
the teeth with right hand helix. hand helix do not touch the teeth
with right hand helix.
Its manufacturing is difficult and Its manufacturing is
requires dedicated machine. comparatively easy as it can be
cut by hobbing, shaping or even
milling.
It has less axial length and thus Other features being same, it
can be used where space is requires more axial space due to
limited. presence of relief gap.
Rack and Pinion Gears

• Rack and pinion

gears are used to
convert rotation
(From the pinion) into
linear motion (of the
rack)

• A perfect example of
this is the steering
system on many cars
Let us see how a Rack and Pinion System of an Automobile
Steering Works

RACK AND PINION STEERING MECHANISM

Straight and Spiral Bevel Gears
 ⦿Bevel gears are used for transmitting power at a
constant velocity ratio between two shafts whose
axes intersect at a certain angle.

⦿ They areusually mounted on shafts that are 90

degrees apart, but can be designed to work at other
angles as well.

⦿ The teeth on bevel gears can be straight, spiral

or hypoid.

⦿ Bevelgear used in marine applications,

automobiles, printing presses,power plants, steel
plants etc.
WORM AND WORM GEAR
⦿Worm gears are used when large gear reductions
are needed. It is common for worm gears to have
reductions of 20:1, and even up to 300:1 or
greater

⦿Many worm gears have an interesting property

that no other gear set has. The worm can easily
turn the gear, but the gear cannot turn the
worm

⦿Worm gears are used widely in material handling

and transportation machinery, machine tools,
automobiles etc
GEAR TRAINS • A gear train is two or more
gear working together by
meshing their teeth and
turning each other in a
system to generate power
and speed

• It reduces speed and

increases torque

• Electric motors are used with

the gear systems to reduce
the speed and increase the
torque
Types of Gear Trains

• Simple gear train

• Compound gear train
• Planetary gear train
Simple Gear Train
• The most common of the
gear train is the gear pair
connecting parallel shafts.
The teeth of this type can
be spur, helical or
herringbone.
• Only one gear may rotate
about a single axis
Compound Gear Train

• For large velocities,

compound
arrangement is
preferred
• Two or more gears
may rotate about a
single axis
Planetary Gear Train
(Epicyclic Gear Train)
 Planetary Gear Train
• They have higher gear ratios.
• They are popular for automatic
transmissions in automobiles.
• They are also used in bicycles for
controlling power of pedaling
automatically or manually.
• They are also used for power train
between internal combustion engine
and an electric motor
Let us see how a Planetary Gear
Train Works...

Functioning of Planetary Gear Train

DESIGN OF SPUR GEARS
Talking about Spur Gear.......
 Spur gears are used to
transmit power and rotary
motion between
parallel shafts.
 If teeth of the gear wheels are
parallel to the axis of wheel, the
gears are called spur gears.
 It is used when axes of the
driving and driven shafts are
parallel and co-planar.
 The smaller of the two gears in
mesh is called the pinion, and
the larger is designated as the
gear.
Law of Gearing

This law may be stated as:

"The shape of the teeth of a

gear must be such that the
common normal at the point
of contact between two teeth
must always pass through a
fixed point on the line of
centers”.

3
4
Gear Terminology
Base circle: In an involute cylindrical gear, the base circle of the
involutes of the tooth profiles is known as base circle.

Circular pitch (p): The distance on the pitch circle from a point
on a tooth to the corresponding point of the adjacent tooth.

Diametric pitch (P): It is defined as the number of teeth of the

gear divided by the pitch circle diameter.

Module (m): It is defined as the pitch circle diameter per unit

number of teeth, i.e,
 Gear ratio :
The ratio of the number of teeth of the wheel (gear) to
that of the pinion is called gear ratio.

Pinion:
The smaller of any pair of mating gears. The larger
of the pair is called simply the gear.

Velocity ratio:
The ratio of the number of revolutions of the
driving (or input) gear to the number of
revolutions of the driven (or output) gear, in a
unit of time.
3
7
Pressure angle (ɸ): The angle between the line of action (a line
through the pitch point and tangential to the base circles) and a
line perpendicular to the line of centers at the pitch point is
known as pressure angle.

Centre distance (C): The distance between the centers of the

two gears in mesh is known as center distance.

Backlash: The difference between tooth space and

tooth width is known as backlash.

Clearance: The difference between the dedendum of one gear

and the addendum of the mating gear is known as clearance.
• Pitch surface : The surface of the imaginary rolling
cylinder (cone, etc.) that the toothed gear may be
considered to replace.

• Pitch circle: A right section of the pitch surface.

• Root (or dedendum) circle: The circle bounding the
spaces between the teeth, in a right section of the gear.
• Addendum: The radial distance between the pitch circle
and the addendum circle.

Dedendum: The distance between the pitch circle and the

root circle.
• Clearance: The difference between the dedendum of one
gear and the addendum of the mating gear.
• Face of a tooth: That part of the tooth surface lying outside
the pitch surface.

• Flank of a tooth: The part of the tooth surface lying inside

the pitch surface.

• Circular thickness (tooth thickness) : The thickness of the

tooth measured on the pitch circle. It is the length of an arc.

• Tooth space: The distance between adjacent teeth

measured on the pitch circle.

• Backlash: The difference between the circle thickness of one

gear and the tooth space of the mating gear.
 Beam strength of spur gear teeth
(Design for Static Load)
The analysis of bending stresses
in gear tooth was done by
Wilfred.

In the Lewis analysis, the gear

tooth is treated as a cantilever
beam as shown in Fig.

The tangential component

Fig : Gear Tooth as Cantilever
causes the bending moment
about the base of the tooth.
 Gear tooth failures

Gear tooth failures

The two basic modes for gear tooth failure are:

1. Breakage of the tooth due to static and dynamic loads,

2. Surface destruction.

The principal types of gear tooth wear are:

1. abrasive wear
2. corrosive wear
3. pitting
4. scoring
 Design Procedure of Spur Gear
• Step 1:- Note down peripheral speed (V)

o Peripheral speed will be same for gear & pinion

o If peripheral speed is not able to find we can
decide any value in between 3 to 15

• Step 2:- Note down the material Properties

o For low velocity decide cast iron & low grade
steel for high velocity
o Note down allowable stresses & BHN from given
material
• Step 3:- Lewi’s Equation
o We need to calculate module
o First from gear & pinion whichever is having small value of for
that only we will apply Lewi’s equation
• Step 4:- Find out weaker element from gear and pinion
Step 5: Tangential Tooth Load:
Velocity Factor

47
Step: 6: b/m Ratio

Step 7:- Velocity Factor

• Step 8:- Calculate gear tooth properties
• Step 9:- Calculate dynamic load using buckingham
equation
• Step 10:- Calculate the beam strength for weaker element

• Step 11:- Calculate wear strength (Fw)

 NOTE

If condition is not safe then change value of

BHN by applying hardening process and
increase the value of it further
 Now, please be ready with:

1. Your Notebooks

2. Design Data Handbook

[or the photocopy of Chapter: Gear]

3. Calculator

Let us start solving a problem on Gear

design exactly the way we do in class
Let us start a problem on Gear Design
Problem:

Two spur gears are to be used for a rock

crusher. The gears are to be designed for
following requirements:
a) power to be transmitted = 18KW
b) Speed of pinion = 1200 RPM
c) Velocity ratio = 3 : 1
d) Gear type = 14 ½o involute
e) No of teeth in the pinion = 24
Make necessary assumptions and design the
gears
Step 1: Given:
1) Machinery where the gears will be used = Stone Crusher
2) power to be transmitted = 18KW = P
3) Speed of pinion = 1200 RPM = NP
4) Velocity ratio = 3 : 1 = VR
5) Gear type = 14 ½o involute
6) No of teeth in the pinion = 24 = ZP
PINION
Step 2: The layout: Let the layout is as shown:

GEAR
Possible alignments
Step 3: Assumptions:

a) The drive is a vertical drive. The gear is placed below the pinion
Step 4: Material Selection for Gear and Pinion

Page 234, Table 12.7:

Let the materials are:

a) Pinion: Steel C 30 (heat treated)

σd = allowable static stress = 220.6 MN/m2; BHN = 300

b) Gear: Cast Steel, 0.20% C, (heat treated)

σd = allowable static stress = 193.2 MN/m2; BHN = 250

[From examination point of view, please consider Table 12.16, p 239 while
making this selection]
Step 3: Assumptions:

a) The drive is a vertical drive. The gear is placed below the pinion

b) Material of Pinion: Steel C 30 (heat treated) and material of Gear:

Cast Steel, 0.20% C, (heat treated)
 Design of the Gear Drive

We have;

a) No of teeth in the pinion = 24 = ZP

b) Speed of pinion = 1200 RPM = NP
c) Velocity ratio = 3 : 1

So, Speed of the gear: 400 rpm = NG

and number of teeth in the gear: 72= ZG
Calculation of Lewi’s Form Factor:

For 14 ½ Degree involute Gear;

y = 0.124 – 0.684/Z

So, Lewis From Factor for Pinion =

By putting Z P in the equation = yP = 0.0955

And Lewis From Factor for Gear=

By putting Z G in the equation = yG = 0.1145

As, we have 24 = ZP and 72= ZG

Calculation of Beam Strength of the Pinion
and the Gear:

For Pinion = (yP x σdP ) = Put the values =

0.0955 x 220.6 MN/m2 = 21.0673 MN/m2

For Gear = (yG x σdG ) = Put the values =

0.1145 x 193.2 MN/m2 = 22.1214 MN/m2

Which one is lesser? The Pinion. The

Pinion is weaker. The design will be based
on the pinion
Design of the Pinion (the smaller Gear)

Calculation of Pitch line Velocity of the pinion:

V = π DP NP/ 60 m/s

As , from 12.1 e, p 203

d = mz; where m = module

So,
V = π x (dP /1000) x (NP/ 60) m/s

V = (π mZP NP/ 60000) m/s

= 3.1416 x m x 24 x 1200/ 60000 m/s
= 1.507968 m m/s……………(1)
Calculation of face width to module ration: (b/m ratio):

As , from 12. 5 f, p 205

9.5m < b < 12.5m

So, 9.5 < b/m < 12.5

b/m ratio is denoted as : k [ 12.8, p 208]

Let
k = b/m = 10……………(2)
Step 3: Assumptions:

a) The drive is a vertical drive. The gear is placed below the pinion

b) Material of Pinion: Steel C 30 (heat treated) and material of Gear:

Cast Steel, 0.20% C, (heat treated)

c) Face Width to Module Ration (k) is assumed to be 10

Calculation of Velocity Factor: (Cv):

Assuming pitch line velocity falls in the range 6 m/s to 20 m/s,

from 12.6 c, page 205

Cv = 6.1 / (6.1 + v)

= 6.1 / (6.1 + 1.507968 m ) ……….…..(3)

from (1)
Step 3: Assumptions:

a) The drive is a vertical drive. The gear is placed below the pinion

b) Material of Pinion: Steel C 30 (heat treated) and material of Gear:

Cast Steel, 0.20% C, (heat treated)

c) Face Width to Module Ration (k) is assumed to be 10

d) Pitch line velocity falls in the range 6 m/s to 20 m/s

Calculation of Tangential Tooth Load: (Ft):

From 12.7 a, page 205

Ft = 1000 P Cs / v

From Table 12.8, p 235

Considering the load on the gear to be light

shock load and 8-10 hours of operation per day

Cs= 1.25

So, Ft = 1000 P Cs / v

= 1000 x 18 x 1.25 / 1.507968 m ……….…..(4)

Calculation of Module: (m):

From 12.5 b, page 204

m = SQRT [Ft/ (σd Cv k Y)]

where k = b/m and Y = π yP

Putting Ft , σd , Cv , k and Y fom (1) , (2), (3) and (4)

We get a non-linear equation of the form:

Am3 + B m+ C = 0………………….(5)

Please calculate and tell me the equation

Let us solve this equation

Am3 + B m+ C = 0………………….(5)

You can use Newton Raphson Method or Secant

Method if Numerical Analysis to Solve the equation

Or Simply use Calculator to find the value of m

Please calculate using Calculator and tell me what is

the value of m = ?? mm
Standardize module ‘m’ from Table
12.2, p – 229; preferably using
Preferred Choice

Nearest higher value of m

m = ?? mm
Once you get the value of m, calculate

a) The diameter of the Pinion= dP = mzP

b) Pitch line Velocity

v = 1.507968 m m/s……………(1)
It should fall in the range 6 m/s to 20 m/s; else redesign

c) Face width of the Pinion (b)

k = b/m = 10……………(2)

d) Tangential Tooth Load =

Ft = 1000 x 18 x 1.25 / 1.507968 m ..(4)
Maximum Error in action between Gears:

From Table: 12.13

for m = calculated value and considering the
gear to be a precision gear
= maximum error in mm e = ????

OR

From Table: 12.14

for v = calculated value of pitch line velocity
in m/s
= e = ???? mm
Calculation of Maximum Dynamic Load (Fd)

Using 12.12 ; p 207

Fd = Ft + [K3 v(Cb + Ft) / K3 v + SQRT(Cb + Ft)]

Where
K3= 20.67 for SI Units
C = from Table 12.12 , p 236
= For 14 ½ Degree Steel and Steel [our case]
for an maximum error in tooth profile of
0.10 mm (Say) = 1103.2
Ft , v, b = Known / calculated

Please Calculate Maximum Dynamic Load (Fd)

Check for the Design:
a) Check for Dynamic Strength of the Pinion:

From 12.16, p – 208; the dynamic Strength

Fs = σd b Y m > Fd

where; Y = π yp
Other parameters are known

Is the Check OKAY?? Please Calculate

b) Check for Wear Load:

From 12.15 a, p – 208; the limiting wear load

Fw = m Z1 b Q K > Fd

where; Q = 2 ZG / (ZP + ZG) [ 12.15 c]

and K ; from Table 12.16 ; p – 239

K = for combination of BHN of 300 and

250 for steel gear and pinion respectively
= 0.814

Check OKAY?? Please Calculate

If both the checks are Okay, then Proceed
further

Otherwise, propose for rectification in the

design
 Other dimensions of the Drive:
Using Table12.3; p 229; the standard dimensions of the drive

Gear Term Dimensions in terms of Dimensions in terms of

Module for Pinion Module for Gear

Addendum (ha) m m
Dedendum (hf) 1.25m 1.25m
Tooth Thickness (t) 1.5708m 1.5708m
Tooth Space 1.5708m 1.5708m
Working Depth 2m 2m
Whole Depth 2.25m 2.25m
Clearance 0.25m 0.25m
Pitch Diameter Z Pm ZGm
Outside Diameter (ZP+ 2_ m (ZG+ 2_ m
Root Diameter (ZP – 2.5)m (ZG – 2.5)m
Fillet Radius 0.4 m 0.4 m
Summary of Results:
Gear Term Dimensions in terms of Dimensions in terms of
Module for Pinion Module for Gear

Material Steel C 30 (heat treated) Cast Steel, 0.20% C, (heat

treated)
BHN 300 250
No of Teeth 24 72
Speed RPM 1200 300
Pressure Angle 14 ½ ° 14 ½ °
Lewis Form Factor 0.0955 0.1145
Allowable Static Stress 220.6 MN/m2 193.2 MN/m2
Beam Strength 21.0673 MN 22.1214 MN/m2
Module m m
PCD mZP mZG
Summary of Results continued:
Gear Term Dimensions in terms of Dimensions in terms of
Module for Pinion Module for Gear

Addendum (ha) m M
Dedendum (hf) 1.25m 1.25m
Tooth Thickness (t) 1.5708m 1.5708m
Tooth Space 1.5708m 1.5708m
Working Depth 2m 2m
Whole Depth 2.25m 2.25m
Clearance 0.25m 0.25m
Pitch Diameter Z Pm ZGm
Outside Diameter (ZP+ 2_ m (ZG+ 2_ m
Root Diameter (ZP – 2.5)m (ZG – 2.5)m
Fillet Radius 0.4 m 0.4 m
The Designed Diagram
 Next Class : Design/Selection of
Bearings

Any Doubt on this Class may be asked

in the Next Class

Thank you