ME 1601: Mechanical System Design

Design of Gear and Gear box

Dr. Vineet Sahoo

Dept. of Mechanical Engineering
National Institute of Technology Jamshedpur

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Learning Objectives
• Study the geometry and kinematics of 4 major types of gearing

• Spur

• Helical

• Bevel

• Worm

• To calculate velocity ratios of different types of gear trains

• To be able to compute meshing forces on gears for use in shaft

and bearing design

• To select gear sizes for satisfying stresses

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Lecture-1

Design of Gears

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Classification of Mechanical Components
Mechanical
Components

Transformation of Supports of Mechanically

Mechanical Power Generated Loads
•Welded Joints
•Fasteners and Non-Permanent Joints
Dissipation Transmission Storage
•Brakes •Springs
•Clutches •Flygear

Fluid to •Gears
Rotational Rotational
rotational •Pulley, Belts and chains
to Linear to
and/or Linear •Bearings
Rotational
•Power Screw •Shafts
•Hydraulic •Couplings, splines, seals
•Pneumatic

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 George Grant and his
Difference Machine George Barnard Grant
Grant’s Difference Engine

In 1876, there was a centennial exhibit in Philadelphia, Pennsylvania. On display

was a working mechanical calculator called ‘ Grant’s Difference Engine’. It was
5ft x 8 ft in size and weighed almost a ton. It could do accurate arithmetic
computation. George Grant didn’t become father of computer, but he is called
father of American Gear Industry
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Gear Drive
Gear drive is used to transmit motion or power between shafts lying at
comparatively shorter distances. Gears are toothed gears, which transmit
motion from one shaft to the other by the meshing of their teeth and a
physical pushing of the teeth of the driven gear by the teeth of the driving
gear. When two gears are running in mesh, the smaller of them is called
the pinion.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Gear Drive - Applications

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Gear Drive – Steering
Mechanism

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Types of gears
According to the position of axes of the shafts.
a. Parallel
Spur Gear
Helical Gear
Rack and Pinion
b. Intersecting
 Bevel Gear
c. Non-intersecting and Non-parallel
 Worm and Worm gear
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Spur gears
• Spur gears are the most common type
of gears. They have straight teeth, and
are mounted on parallel shafts.
Sometimes, many spur gears are used at
once to create very large gear reductions

•Teeth is parallel to axis of rotation

•Transmit power from one shaft to another parallel shaft

• Easy to Maintain & Manufacture.

• Generates radial loads only on shaft.

• Each time a gear tooth engages a tooth on the other gear, the teeth collide,
and this impact makes a noise. It also increases the stress on the gear teeth.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Spur gears

Gear and Pinion rotates in opposite direction

Dr. Vineet Sahoo, MED, NIT Jamshedpur
Spur gears

Internal Gear and Pinion rotates in same direction

Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Helical Gears
• Helical gears are used to transmit power
between two parallel shaft.

• The teeth are inclined to the axis.

• Hence, for the same width, their

teeth are longer than spur gears and
have higher load carrying capacity.

• Their contact ratio is higher than spur gears and they operate smoother and
quieter than spur gear.

• Due to their angular cut, teeth meshing results in thrust loads along the gear
shaft. This action requires thrust bearings to absorb the thrust and maintain
gear alignment.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Herringbone gears

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Bevel Gear
•To transmit motion
between shafts with axis
intersecting with each
other at certain angle.

•It has a conical form with

teeth cut over the cone.

•Bevel gears with equal

numbers of teeth and
shaft axes at 900 are called
miter gears

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Types of Bevel
Gears

Straight Spiral Bevel

Bevel
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Types of Bevel
Gears Hypoid Bevel gears

 Hypoid gears are quite similar

to spiral bevel gears except that
the shafts are offset and non-
intersecting

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Rack has series of teeth cut parallel to each other along a
straight blank.
 Same tooth pitch for rack and pinion.
Dr. Vineet Sahoo, MED, NIT Jamshedpur
• Motion transmitted between the shafts with axis perpendicular to each
other
• Same Tooth pitch between mating & large gear reduction ratio is possible
in a single stage.
• The gear outer surface is either straight or concave face with the radius of
curvature equal to the inner radius of the worm.
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Spur Gear terminology

Profile:
Bottom
Top
Flank:
Face:land:
Depth
Width Itof
Dedendum:
Pitch
Addendum: ItItis
land:
circle:
Dedendum
Root istooth:
clearance:
Addendum
Thickness is
It
the
the
ofthe
gear:isPitch
ItIt
bearing
circlethe
circle:surface
Itcurve
is
tooth:is the
surface
isisthe
ItItthe
circle
or
is
It the surface
forming
surface
of
part
root
the
Itis sum
is
isthe the
of
of the
ofdedendum.
of
of
the
acircle
width the
top
the
isface
addendum
theoretical
the
difference
circle:
the ofIttooth
the bottom
of
addendum
and
the
below
above tooth.
the
and
circle
between
the
passing
thickness space
ofcircleof the
theflank.
upon
between
the
through
tooth, tooth
dedendum.
pitch
which
passing
the space.
The
endsworking
circle.
teeth all
through
outer
measured along the
depth
the
dedendum
of of a along
computations
measured
bottom
the
pitch teeth
circle. gear
of of
and
of aisthe
the the the
gears
gear.spaces.depth
are
addendum
pitch
Its of engagement
based.
circle.
diameter of The
the pitch
mating
is the ofgear.
largest a diameter.
pair
circles of of gears
a pair ofthat is it
is the sum
mating gears of are
theirtangentaddendums. to each other. The diameter of the pitch
circle is called the pitch diameter.
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Spur Gear terminology

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Spur Gear terminology

Hobbing- Helical Spur Hobbing-Straight Spur

Gear
Shaping

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Gear tooth profiles

Commonly used profiles of the tooth are

(i) Involute
(ii) Cycloidal

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 1

1’

2’
1

2
Fig.- 1. A cross belt drive and it’s
replacement by conjugate profiles.

Profiles to Shape Gear Tooth

C Epicycloid
Involute

Addendum
Circle
Pitch P
Circle
E Pitch
Base Circle Circle
900 B
Dedendum
Circle Pressure
Line
Hypocycloid
α D

Generating
Circles

( a) ( b)
Involute Dr. Vineet Sahoo, MED, NIT JamshedpurCycloidal
Law of Gearing

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Law of Gearing
Fundamental Law of Toothed Gearing Gearing laws of Constant Velocity can be derived as follows:
K 1 M 1  1 
O1 K1
K1 M 2  2  O2
 K2  K1 M 2 
1 OK KM
O11 K1 2 1 1 1

O1 K1  O1

As O1 K1 A  A1 M 1 K1 N 1
K
K1 N1M1
K1 M 2 K1
O2 K 1  O2 B
N1
 OA OP
2 1 1 =Constant
1  O 2 B  O 2 P

Fig.- 4. Gearing laws of Constant

Velocity.
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Comparison with Involute & Cycloidal profiles wrt gear tooth:
Involute
Cycloidal
1. Line of action Straight Curved
2. Radial component
of Normal load
Constant Vary

3. Effect due to change Gearing law remain Gearing law is

in centre distance Unaffected violated
4. Beam strength of tooth - Cycloidal tooth has
better strength
capacity.
5. Tooth generation Involute tooth generation Relatively Expensive
is easy and less expensive

6. Interchangeability Possible Not Possible

7. Interference & Undercut Occur Do not occur

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Gear Trains
• When two or more gears are made to mesh with each other to
transmit power from one shaft to another. Such an arrangement is
called gear train. The train used depends upon the velocity ratio
required and the relative position of the axes of shafts.
 A gear train may consist of spur, bevel or spiral gears.
 Simple gear train
 Simple gear train with idler
 Compound gear train

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Simple Gear Train

Arrangement of gears in series is known as simple gear train.

Two meshed gears will rotate in opposite directions.

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Simple Gear Train

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Simple Gear Train with Idler

An Idler Gear allows the drive and driven gears to rotate in the same
direction. It also cover the space between the driver and driven gears

Application - Paper Transport Rollers

Dr. Vineet Sahoo, MED, NIT Jamshedpur
Simple Gear Train with
Idler

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Compound Gear
Train

Gear D
Gear B
Gear A
Gear C

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Compound Gear Since gear 1 is in mesh with gear 2,
Train therefore its speed ratio is
𝑁1 𝑍2
=
𝑁2 𝑍1
Similarly, for gears 3 and 4,
speed ratio is
𝑁3 𝑍4
=
𝑁4 𝑍3
and for gears 5 and 6,
speed ratio is
𝑁5 𝑍 6
=
𝑁6 𝑍5
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Compound Gear Train – Velocity Ratio
The speed ratio of compound gear train is obtained by
multiplying the equations
𝑁1 𝑁3 𝑁5 𝑍2 𝑍4 𝑍6
× × = × ×
𝑁2 𝑁4 𝑁6 𝑍1 𝑍3 𝑍5

Since gears 2 and 3 are mounted on one shaft B,

therefore N2 = N3. Similarly gears 4 and 5 are mounted
on shaft C, therefore N4 = N5.
𝑁1 𝑍2 𝑍4 𝑍6
= × ×
𝑁6 𝑍1 𝑍3 𝑍5

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Compound Gear Train – Velocity
Ratio

Dr. Vineet Sahoo, MED, NIT Jamshedpur

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

Z1+Z2=Z3+Z4

𝑁1 𝑍2 𝑍 4
= ×
𝑁4 𝑍1 𝑍 3

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Planetary Gear Train – Velocity Ratio

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Planetary Gear Train – Humpage Gear
Train

Humpage speed reduction gear was originally designed as a substitute for

back gearing of a lathe, but its use is now considerably extended to all kinds of
workshop machines and also in electrical machinery
Dr. Vineet Sahoo, MED, NIT Jamshedpur
Planetary Gear Train – Differential
Gear-Train

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Planetary Gear Train – Velocity Ratio

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Planetary Gear Train – Problem-1
An Epicyclic speed reducer gear is
shown in the figure. The driving
shaft carries on the arm A a pin, on
which the compound gear B-C is
free to revolve. gear C meshes
with the fixed gear E and gear B
meshes with a gear D that keyed
to the driven shaft.
The number of teeth on the gear
are:
Zb=27; Zc=30; Zd=24;
Ze=21;

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Planetary Gear Train – Problem-2

In the planetary gear train shown in the figure,

gear A is the driver and gear B and D are
compounded. Gear E and C are internal gears
with C as the fixed gear. Number of teeth on
gears are:
ZA=20; ZB=60; ZC=140; ZD=40;
ZE=120;
If the driver gear rotates at 720 rpm c.c.w.
when seen from right. Find out the speed at
which driven gear rotates?

Dr. Vineet Sahoo, MED, NIT Jamshedpur

Planetary Gear Train – Problem-3
In an epicyclic gear train of the sun and planet type as
shown in figure, the pitch circle diameter of the annular
wheel is to be nearly 216 mm and module 4 mm. when the
annular wheel is stationary, the arm/spider which carries
three planet wheel of equal size, is to make one revolution
for every five revolution of the driving spindle carrying the
sun wheel.
Determine suitable number of teeth for all the wheels and
the exact diameter of the pitch circle of the annular wheel. If
the input torque of 19.6 N-m is applied to the spindle
carrying the sun wheel; determine the fixing torque on the
annular ring

Dr. Vineet Sahoo, MED, NIT Jamshedpur

 Advantages of Gear Drives:
 positive drives, with no slip.
 most convenient and efficient for small distances
 can operate for any axes inclinations and also when
axes are not in one plane
 velocity ratio remains constant throughout
 can be used for any power transmission
 are applicable to high velocity ratios, say up to 60: 1
 gear can be made of metals as well as non metals
 have high transmission efficiency
 can be casted as integral part of shaft
Dr. Vineet Sahoo, MED, NIT Jamshedpur
 Disadvantages of Gear Drives:

 Not suitable for large distances

 Need lubrication
 more vibrations and noise
 manufacture of gears is costly
 when more number of gears used (gear
train) weight of machine increases.

Dr. Vineet Sahoo, MED, NIT Jamshedpur