LEARNING GUIDE

Week No.: __10__

TOPIC:

DIFFERENTIAL INDEXING

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Calculate the required indexing given number of divisions using differential

indexing formula.

2. Perform/familiarize angular indexing in milling machine.

II. CONTENT/TECHNICAL INFORMATION

Differential Indexing – any number of divisions up to approximately 2000,

which, when written under 40 cannot be reduced to a factor of one of the numbers
of holes contained in the index plate, may be done by differential indexing.

This type of indexing is accomplished through the use of a geared differential

connecting the index plate with the spindle, having the worm engaged with the
40
worm wheel. The formula for this type of indexing is (n-N) .
n

where: N is the number of divisions to be indexed;

n is a selected number within the range of plain indexing and
approximately equal to N;

40
reduced to its lowest terms is the ratio of the number of holes to expand the
n
sector arms to the number of holes in the index plate circle. The product of (n –
40
N) and is the gear ratio. The standard gears furnished with the Brown &
n

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Sharpe dividing head are: two 24’s, and one each of 28, 32, 40, 44, 48, 56, 64, 72,
86, and 100. Special gears are: one which of 46, 47, 52, 58, 68, 70, 76, and 84.

Method of Calculating the change gears:

A = approximate number of divisions

N = required number of divisions

- If A is greater than N, resulting fraction is positive and the index plate must move
in same direction as crank (clockwise). This positive rotation uses an idler gear.
- If N is greater than A, resulting fraction is negative and index plate must move
counterclockwise. This negative rotation required use of two idler gears.

Gearing:

Simple - One idler for positive rotation of index plate and two idlers for negative
rotation

Compound - One idler for negative rotation of index plate and two idlers for
positive rotation.

Example.

To illustrate the use of this formula, suppose that is necessary to index 96

divisions.

Solution:

First test the number to determine whether plain or differential indexing

will be required. This done by writing 96 under 40 and reducing the fraction to its
lowest terms, to determine whether or not the denominator is a factor of one of the
numbers of holes in one of the index plates.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 40 5
Since reduces to and since 12 is not a factor of any of the sets of
98 12
holes it is obviously a differential indexing problem

40
Therefore selecting 98 as the value for n the formula reads, (98 – 96)
98

40 20
Reducing to its lowest terms gives or 20 holes in the 49-hole circle; the
98 49
gear ratio is equal to

40 40 20 40
(98 – 96) x or 2 x or 2 x =
98 98 49 49

This gear ratio can be arranged into compound gears to suit the standard
gears furnished with the Brown & Sharpe dividing head as follows:

40 5 8 5 8 40 8 4 32
= x
49 7 7
x =
7 8 56
x =
7 4 28

40 32
Therefore, the gear compound is x . Observe that when a number in
56 28
the denominator position is raised to suit a standard gear, a number in the
numerator position must be multiplied by this same value to maintain the proper
ratio.

The gear compound is arranged on the dividing head as follows:

A = 40 = gear on spindle B = 32 = first gear on stud

C = 56 = second gear on stud D = 28 = gear on worm

To have the gear differential make up the difference between the required
number of divisions N, and the selected number of divisions n, it is necessary to
have the index plate rotate in the correct direction relative to the crank.

If (n – N) is positive the index plate must rotate in the same direction as

the crank is turned. If (n – N) is negative the index plate must rotate in a direction
opposite to that of the crank.

When the gearing is simple and (n – N) positive, use one idler gear.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
When the gearing is simple and (n – N) negative, use two idler gears.

When the gearing is compound and (n – N) positive, use no idler gears.

When the gearing is compound and (n – N) negative, use two idler gears.

Therefore, the compound gears of the preceding illustration require the use
of no idler gears, so that the index plate will rotate in the same direction as the
crank, thus making up the difference between the required number of divisions,
96, and the selected number of divisions, 98.

Example:

Calculate the indexing for cutting 323 divisions.

Solution:

40
Formula is (n – N) , Let n = 320.
n

40
Substituting the correct values, we obtain: (320 – 323) .
320
40 1 1 1 2 2
= ; raise to terms of indexing; thus, x = or 2 holes in the 16-
320 80 8 8 2 16
1 1 3
hole circle. Continue as follows to find the gear ratio; (320 – 323) = 3 x = .
8 8 8

3 3 8 24
Raising to standard gears, x = .
8 8 8 64

Place the 24-tooth gear on the spindle and the 64-tooth gear on the worm
shaft. Since the gearing is simple and (n – N) is negative, two idler gears are
necessary so that the index plate will travel in the proper direction relative to the
crank. The complete answer is:

Gears = with 2 idler gears

It is absolutely necessary when doing differential indexing to have the

index plate locking pin disengaged from the plate, otherwise it will be shared off.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Most milling machine manufacturers can, and do, furnish indexing charts
that are intended for use with their dividing heads. These charts eliminate the
necessity of calculating the indexing for commonly used numbers of divisions. If
possible, get copies of these charts and practice using them. The standard gears
furnished with a Brown & Sharpe dividing head are: two with 24 teeth and one
each of the following: 28, 32, 40, 44, 48, 56, 64, 72, 86 and 100.

III. PROGRESS CHECK

Using the Brown & Sharpe dividing head with the above standard gears and
the differential indexing formula, calculate the indexing for the following:

BROWN & SHARPE

Plate No.1 15, 16, 17, 18, 19, 20

Plate No.2 21, 23, 27, 29, 31, 33

Plate No. 3 37, 39, 41, 43, 47, 49

1. 177 divisions 6. 818 divisions

2. 83 divisions 7. 914 divisions
3. 77 divisions 8. 1300 divisions
4. 61 divisions 9. 1623 divisions
5. 263 divisions 10. 1124 divisions

IV. REFERENCES

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley
Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

This module is a property of Technological University of the Philippines Visayas and intended

for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7 th Edition,
Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

LEARNING GUIDE

Week No.: __11__

TOPIC:

ANGULAR INDEXING

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Calculate the required indexing given angle using angular indexing procedure.

2. Perform/familiarize angular indexing operation in milling machine.

II. CONTENT/TECHNICAL INFORMATION

Angular indexing – this kind of indexing is done about the same as plain
indexing, the exception being that the work must be indexed through an angle
rather than a certain number of divisions.

One revolution of the index crank equals 1/40th of a revolution of the

spindle. 1/40 x 360◦ = 9 degrees, or 540 minutes, or 32 400 seconds of arc on the
40 to 1 ratio dividing head.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Since one revolution of the crank causes the spindle to rotate through 9 ◦,
then to rotate the spindle through any other number of degrees would require as
many turns of the crank as the number 9 is contained in the required angle. For
example, suppose it is required to index an angle of 27 ◦. The number of
revolutions of the crank required to index this angle is 27/9 or 3. In other words,
to determine the number of revolutions of the crank necessary to index a given
angle, divide the given angle in degrees by 9; or the given angle, change to
minutes, by 540; or the given angle changed to seconds, by 32,400.

The following examples are intended to acquaint the student with the
simpler forms of angular indexing. More complicated types can be handled by
means of a rather complicated mathematical procedure known as “continued
fractions,” which is beyond the scope of an elementary text.

Example 1.

Required to index an angle of 17◦24’

Solution:

Change 17◦24’ to minutes as follows:

17◦24’ = (17 x 60) + 24 = 1020 + 24 = 1044’. One turn of the crank equals 540’;
therefore, to index 1044’ the crank will have to be turned as many times as 540 is
contained in 1044.

504 14
1044 / 540 = 1 or 1 rev
540 15

Since one of the standard index plates contains a 15-hole circle, the
complete answer will be one revolution of the crank and 14 holes in the 15-hole
circle. Set the sector arms for 14 holes in the 15-hole circle with the left arm up
against the index pin, which should be placed in any convenient hole of the 15-
hole circle; then turn the index crank once, and on through to the right arm.

Fractional parts of a turn which are very nearly equal to a whole turn such
as 14/15, 30/33, etc., require the sector arms to be set and the crank turned

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
through arc Y instead of X. That is, the crank must be turned through an arc
outside of the sector arms instead of inside.

Example 2.

Required to index an angle 72◦15’38”

Solution:

Change 72◦15’38” to seconds as follows:

{[(72 x 60) + 15]60} + 38 = {[4320 +15]60} + 38 = {4335 x 60} + 38 = 260,100

+ 38 = 260,138”

One turn of the crank equals 32,400 seconds; therefore, to index 260,138
seconds the crank will have to be turned as many times as 32,400 is contained in
260,138”.

260,138 / 32, 400 = 8.02895 or approximately 8.0290 revolutions of the crank.

The whole number is the complete number of revolutions of the crank.

The fractional part, 0.0290, is found, by consulting angular indexing charts in
handbooks, to be very close to 0.0303 which is given as one hole in the 33-hole
circle.

The complete answer is 8 revolutions and one hole in the 33-hole circle.

While this does not give precisely the required angle, it is close enough for
all practical purposes, the error being equal to (0.03030 – 0.02895) x 32,400 =
43.74”. Remember this is the error in an angle of 72 ◦15’38”, which is less than the
guaranteed accuracy of standard dividing heads.

III. PROGRESS CHECK

Calculate the indexing for the following angles:

1. 7○
2. 11○ 35’
3. 14○ 57’ 30’’

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
4. 15○
5. 17○ 11’ 38’’
6. 23○ 45’
7. 37○
8. 19○ 50’
9. 54○ 42’ 28’’
10. 25○

IV. REFERENCES

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley
Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7 th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

This module is a property of Technological University of the Philippines Visayas and intended

for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 LEARNING GUIDE

Week No.: __12__

TOPIC:

LINEAR GRADUATING

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Calculate the required turns and spaces using continued fraction.

2. Perform/familiarize linear graduating on straight/flat surface in milling

machine.

II. CONTENT/TECHNICAL INFORMATION

Graduating – this kind of work is performed in much the same manner as plain
indexing with the exception that it is required to move the milling machine table a
specified distance through the medium of the dividing head. The dividing head

This module is a property of Technological University of the Philippines Visayas and intended

for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
spindle is geared to the lead screw on the mill table. When even gears are used to
connect the spindle with the lead screw, one revolution of the index crank will
move the mill table one-fortieth of the lead of the lead screw.

For example, if the mill table has a lead screw with 4 threads per inch, the
lead will be 0.250”, and 1/40 of this is 0.00625”. One revolution of the index
crank, under these conditions, moves the table 0.00625”. From this relationship
the formula

R = D / 0.00625

is developed, where D is the distance the table must be moved for each
graduation, and R is the number of revolutions of the index crank.

Example 1.
Required to cut graduations with 0.010” spaces.

Solution:
Using the formula R = D / 0.00625
375 3
R = 0.010 / 0.00625 = 1 = 1 revolutions of the crank. Three-fifths of
625 5
revolutions can be made by using either the 15-hole circle or the 20-hole
circle.
3 3 3 9
If the 15-hole circle is used, change to 15ths; x = Set the sector arms
5 5 3 15
for 9 holes in the 15-hole circle.
3 3 4 12
If the 20-hole circle is used, change to 20ths; x = . Set the sector
5 5 4 20
arms for 12 holes in the 20-hole circle.
The complete answer is 1 revolution of the crank and 9 holes in the 15-hole
circle or 1 revolution and 12 holes in the 20-hole circle.

Example 2.
Required to cut graduations 0.03162’’ apart.

Solution:

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 0.03162 / 0.00625 = 5.0592 revolutions of the crank. Five is the complete
number of revolutions of the crank.
By referring to the chart, “Longitudinal Graduating”, furnished with the
Brown & Sharpe dividing head, the nearest decimal fraction to 0.0592 is
0.059215 which equals 18 holes in the 19-hole circle. The error per
graduation is equal to (0.059215 x 0.00625) – (0.0592 x 0.00625) =
0.00037009 – 0.00037000 = 0.00000009’’.
The complete answer is 5 revolutions of the crank and 18 holes in the 19-
hole circle. Error equals + 0.00000009’’ per graduation.

If it is desired to cut graduations in vernier plates or flat rules and scales,

the work should be clamped directly to the table, lengthwise of the table. The
cutting tool is usually a fly cutter ground to a sharp V-point and placed in the
fly tool arbor in the spindle, so that it will cut the line as the table is traversed.

It should be remembered in graduating that the crank must always be

turned in the same direction in order to prevent backlash between the index
crank and the table feed screw.

III. PROGRESS CHECK

Calculate the indexing necessary to cut graduations of the following sizes:

1. 0.0195’’ 6. 0.1385’’
2. 0.0255’’ 7. 0.2452’’
3. 0.0447’’ 8. 0.3498’’
4. 0.07325’’ 9. 0.4607’’
5. 0.0964’’ 10. 0.00832’’

This module is a property of Technological University of the Philippines Visayas and intended

for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
IV. REFERENCES

Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley
Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7 th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

LEARNING GUIDE

Week No.: __13__

TOPIC:

GEARS & GEAR CUTTING TERMINOLOGIES

I. EXPECTED COMPETENCIES

At the end of the topic, the student should be able to:

1. Familiarize gear terminologies, parts, types and operations.

2. Calculate problems solving regarding different types of gears.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
II. CONTENT/TECHNICAL INFORMATION

Gears are toothed cylindrical wheels used in transmitting motion and

power from one rotating shaft to another. Depending on the design and
construction of the gear pair employed, gears can change the direction of
movement and/or increase the output speed or torque.

 Classification of Gears According to the Nature of Axis

I. Parallel Axis
 External Spur Gear
 Internal Spur Gear
 Twisted Spur Gear
 Herringbone Gear
 Rack & Pinion
 Pin Gearing
II. Intersecting Axis
 Plain Bevel Gear
 Crown Bevel Gear
 Spiral Bevel Gear

III. Non-intersecting Axis

 Hyperboloidal
 Hypoid
 Screw gears

 Kinds of Gears
 Spur Gears
 Helical Gears
 Worm Gears
 Bevel Gears

 Spur Gears

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Spur gears are toothed wheels whose tooth elements are straight and parallel to
the shaft axis; they are used to transmit motion and power between parallel shafts.
The curve shape of the faces of the spur gear teeth has a special geometry called
involute curve.

Figure 13.1 Spur Gear Geometry

(Source: https://www.sdp-si.com/resources/elements-of-metric-gear-technology/images/Fig2-1.jpg)

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 Figure 13.2 Gear Tooth
(Source: https://image.slidesharecdn.com/geartoothterminology-150323072734-conversion-
gate01/95/gear-tooth-terminology-2-638.jpg?cb=1427095819)

 Gear Terminologies

Pitch circle – is the basis of measurement of gears. It is also the trace of the pitch
cylinder (pitch surface) as it intersects a plane normal to the axis.
Pitch diameter – the size of a gear is its pitch-circle diameter in inches
Pitch point of meshing gears – is the point of tangency of the pitch circles; for
an individual gear, the pitch point will be located where the tooth profile cuts the
standard pitch circle.
Addendum circle (also outside circle) – is the circle that bounds the outer ends
of the teeth. The addendum cylinder encloses a gear. The diameter of this is called
the outside diameter.
Addendum (a) – is the radial distance between the pitch circle and addendum
circle.
Dedendum circle or root circle – is the circle that bounds the bottoms of the
teeth.
Dedendum (d) – is the radial distance from the pitch circle to root circle, that is,
to the bottom of the tooth space.
Whole depth – is equal to the addendum plus the dedendum.
Working depth – is the radial distance from the addendum circle to the working
depth circle which marks the distance that the mating tooth projects into the tooth
space; it is the sum of the addendums of mating gears.
Clearance – is the radial distance between the working depth circle and the root
circle; it is the dedendum minus the mating addendum.
Circular thickness – also called tooth thickness, is the width of tooth measured
along the pitch circle.
Chordal thickness – is the tooth width measured along the chord at the pitch
circle.
Width of space – or tooth space is the space between teeth measured along the
pitch circle.
Backlash – is the tooth space minus the circular thickness. When backlash exists
between two gears, one gear can be turned through a small angle while the mating
gear is held stationary.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Face width – is the length of teeth in an axial direction.
Face of the tooth – is the surface of the tooth between the pitch cylinder and the
addendum cylinder.
Flank – is the surface of the tooth between the pitch and root cylinders.
Top land – is the surface of the top of the tooth.
Bottom land – is the surface of the bottom of the tooth space. When two gears
are in mesh, the smaller is called the pinion and the larger the gear.
Angle of action – is the angle through which the gear turns from the time a
particular pair of teeth come into contact until they go out of contact.
Arc of action – subtends the angle of action.
Angle of approach – is the angle through which the gear turns from the time a
particular pair of teeth come into contact until they are in contact at the pitch
point.
Angle of recess – is the angle through which the gear turns from the time given
pair of teeth are in contact at the pitch point until they pass out mesh. The angle of
approach plus the angle of recess is equal to the angle of action.
Velocity ratio mw – is the angular velocity of the driver divided by the angular
velocity of driven gear. For spur gears, this ratio varies inversely as the pitch ( or
base-circle) diameters and as the tooth numbers.
ω 1 n1 D 1 N 1
mw = = = =
ω2 n2 D 2 N 2
where n is angular velocity in, say revolutions per minute, the subscript 1 refers to
the driver, and the subscript 2 refers to the driven gear.
Gear ratio (mg) – is the number of teeth in the gear divided by the number of
teeth in the pinion. When the pinion is the driver, mg = mw.

Figure 13.3 Base Circle & Pressure angle

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q=tbn:ANd9GcQa5m6kJwfxfDhJZ1muDSyVtwXAKqUUJYzOvA&usqp=CAU)

Base Circle – is the circle from which the involute is generated.

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Pressure angle of a gear - is also the angle between the line of action and the line
tangent to the pitch circles of mating gears.

Line of action – all points of contact between mating teeth properly lie somewhere on
this line, which is also the generating line.

Pitch of a gear – is a measure of the spacing, and usually also of the size of the tooth.

Circular pitch (Pc) – is the distance in inches measured along the pitch circle
from a point on one tooth to the corresponding point on an adjacent tooth.

Diametral pitch (Pd) – is the ratio of the number of teeth per inch of pitch
diameter.

Base pitch (Pb) – (involute gearing only) is the distance in inches measured along
the base circle from a point on one tooth to the corresponding point on an adjacent tooth.
It is also the distance between parallel profiles on adjacent teeth measured along the
generating line.

Pitch angle – is the angle subtended by an arc on the pitch circle equal in length to the
circular pitch.

Length of action (Z) – is the length of that part of the line of action between the initial
and final points of contact

Contact ratio (mc) – is the ratio of the angle of action to the pitch angle; the ratio of
length of action to the base pitch; the ratio of the arc of action to the circular pitch.

SPUR GEAR FORMULAS

1. Circular Pitch
πDp πDg
Pc = Pc = Pc = πM
Np Ng

2. Diametral Pitch
Np Ng π 1
Pd = D p Pd = D g Pd = P c Pd = M

Where: Pc = circular pitch (mm/tooth or in/tooth)

M = module
Pd = diametral pitch (tooth/mm or tooth/in)

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 Dg = gear diameter (mm or in.)
Dp = pinion diameter (mm or in.)
Ng = number of teeth in gear
Np = number of teeth in pinion
3. Clearance
c=d–a c = W - Wr

Where: a = addendum (mm or in.)

d = dedendum (mm or in.)
W = whole depth (mm or in.)
Wr = working depth (mm or in.)
c = clearance
4. Addendum
1
a = Pd

5. Dedendum
1○ 1 ○
a. For 14 and 22
2 2
1.157
d = Pd

b. For 20○ and 25○

1.25
d = Pd

6. Outside diameter
a. For Pinion
Dop = Dp + 2a = (Np + 2) / Pd

b. For Gear
Np+ 2
Dog = = Dg + 2a
Pd

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 Where: Dop = outside diameter of pinion (mm or in.)
Dog = outside diameter of gear (mm or in.)
7. Root Diameter
a. For Pinion
Drp = Dp - 2a

b. For Gear
Drg = Dg – 2d

Where: Drp = root diameter of pinion (mm or in.)

Drg = root diameter of gear (mm or in.)
8. Whole depth
W=a+d W = Wr + c

9. Working depth
Wr = 2a Wr = W – c

10. Tooth thickness

a. For Backlash is zero
Pc
T=
2
b. For Backlash is not zero
Pc − B
T=
2

Where: T = tooth thickness (mm/tooth or in./tooth)

Pc = Circular pitch (mm/tooth or in./tooth)
B = Backlash (mm or in.)

11. Tooth Space

S=T+B

Where: S = tooth space or space width (mm or in.)

12. Base Circle diameter

a. For Pinion
Dbp = Dp cos Φ

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 b. For Gear
Dbg = Dg cos Φ

Where: Dbp = base circle diameter of pinion (mm or in.)

Dbg = base circle diameter of gear (mm or in.)
Φ = pressure angle (deg.)

13. Center distance between gears

Dg+ Dp
C= for external contact
2

Dg− Dp
C= for internal contact
2

Where: C = center distance between gears (mm or in.)

14. Backlash
B=S–T

0.03 0.04
B= ¿
Pd Pd

 Helical Gears

Helical gears are similar to spur gears except that their teeth are cut at an
angle to the hole (axis) rather than straight and parallel to the hole like the teeth of a
spur gear. The line of contact between two teeth is not parallel to the teeth but
inclined.

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 Figure 13.4 Helical Gears
(Source:
https://lh3.googleusercontent.com/proxy/Ek_PduGyZCs2k597godC2_93vNkPaZHfd_TC5tKIC6UGIYijwe1zxPatjTa
1X74QjB0qdJXtMeD7agH3Woi5HJfcuyY)

Figure 13.5 Helical Tooth

(Source: https://ars.els-cdn.com/content/image/3-s2.0-B9780750673280500410-f39-06-9780750673280.gif)

Terminologies:

 Helix angle – is the angle between a tangent to the pitch helix and an intersecting
axial element of the pitch cylinder.

 Axial pitch - is the distance, parallel to the axis, between similar faces of adjacent
teeth. ...

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
  Normal pitch - The normal pitch of a helical gear is the pitch of the tool used to
cut the teeth.

Figure 13.6 Helical gear geometry and forces

(Source: https://slideplayer.com/slide/4644863/15/images/3/Helical+gear+geometry+and+forces.jpg)

Formulas in Helical Gear

1. Tangential Force
Fr
Ft =
tan Φ

Where: Ft = tangential force (N or lb.)

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 F r = radial force (N or lb.)
Φ = pressure angle (degree)
2. Radial Force
Fr = Fn sin Φ

Where: Fn = normal force (N or lb.)

3. Axial Force
Fa = Ft tan φ
Where: Fa = tangential force (N or lb.)
φ = helix angle (deg)
4. Normal Pressure angle
Φn = tan −1(tan Φ cos φ)

Where: Φ n = normal pressure angle (deg)

5. Axial Pitch
Pcn π
Pa = =
tan φ Pd tan φ

Where: Pa = axial pitch

Pcn = normal circular pitch

6. Normal Diametral Pitch

Pd
Pdn =
cos φ

Where: Pdn= normal diametral pitch

7. Normal Circular Pitch
Pcn = Pc cos φ

Where: Pc = circular pitch

8. Lead
L = Pa for single helix
L = 2Pa for double helix
L = 3Pa for triple helix
L = nPa for multiple helix

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
  Bevel Gears

Bevel gears are gears where the axes of the two shafts intersect and
the tooth-bearing faces of the gears themselves are conically shaped. Bevel gears
are most often mounted on shafts that are 90 degrees apart, but can be designed to
work at other angles as well. The pitch surface of bevel gears is a cone.

Figure 13.7 Bevel Gear

(Source: https://i.pinimg.com/originals/b4/f3/a5/b4f3a505d417ad1876f353555ba52a47.png)

Types of Bevel Gears

1. Straight bevel gears 4. Hypoid gears

2. Spiral bevel gears 5. Spiroid gears
3. Zerol bevel gears

Straight bevel gears – are usually used for pitch-line velocities up to 1000 ft/min
(5m/s) when the noise level is not an important consideration. They are available
in many stock sizes and are less expensive to produce than other bevel gears.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Figure 13.8 Straight bevel gear
(Source:
https://www.globalspec.com/ImageRepository/LearnMore/20121/beveldiagramaee92748bdbf48849cfeb35e4d1be26
6.png)

Spiral bevel gear – is the one with spiral angle. These gears are recommended
for higher speeds and where the noise level is an important consideration. Spiral
bevel gears are the bevel counterpart of the helical gear. The pitch surfaces and
the nature of contact are the same as for straight bevel gears except for the
differences brought about by the spiral-shaped teeth.

Zerol bevel gear – is a patented gear having curved teeth but with a zero spiral
angle. The axial thrust loads permissible for Zerol bevel gears are not as large as
those for the spiral bevel gear, and so they are often used instead of straight bevel
gears. The Zerol bevel gear is generated by the same tool used for regular spiral
bevel gears.

Hypoid gears – are gears frequently desirable, as in the case of automotive

differential applications, to have gearing similar to bevel gears but with the shafts
offset. These gears are called hypoid gears, because their pitch surfaces are
hyperboloids of revolution. The tooth action between such gears is a combination
of rolling and sliding along a straight line and has much in common with that of
worm gears.

Spheroid Gears – are similar to hypoid gears but will relatively differ from their
shaft offsets. Hypoid gear has relatively small shaft offset, for the larger offsets,

This module is a property of Technological University of the Philippines Visayas and intended

for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
the pinion begins to resemble a tapered worm and the set is then called spiroid
gearing.

Formulas in Bevel Gears

ω=ϒ-𝝳
1. Cutting or Root Angle

Where: ω = cutting angle (deg)

𝝳 = dedendum angle (deg)

ϒ = pitch angle (deg)

2. Face Angle
β=ϒ+α
Where: β = cutting angle (deg)
α = addendum angle (deg)
3. Pitch Angle
a. For pinion
−1 Rp −1 Np
ϒp = tan ϒp = tan
Rg Ng

b. For gear

−1 Rg −1 Ng
ϒg = tan ϒg = tan
Rp Np

Where: Rp = radius of the pinion (mm or in.)

Rg = radius of the gear (mm or in.)
Np = number of teeth of pinion
Ng = number of teeth of gear
ϒp = pitch angle of the pinion (deg)
ϒg = pitch angle of the gear (deg)
4. Face Width
L
b<
3

Where: L = length of the cone (mm or in.)

b = face width (mm or in.)

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 5. Length of Cone

L = √ Rp2+ Rg 2

6. Working depth

2
Wr =
Pd

Where: Wr = working depth

Pd = diametral pitch
7. Total Depth

2.188
Wr = + 0.002
Pd

 Worm gears

Worm gears are used to transmit power between non-intersecting shafts,

nearly always at right angles to each other.

Worm gears are constructed of a worm and a gear (sometimes referred to as a

worm wheel), with non-parallel, non-intersecting shafts oriented 90 degrees to
each other. The worm is analogous to a screw with a V-type thread, and the gear
is analogous to a spur gear. The worm is typically the driving component, with the
worm’s thread advancing the teeth of the gear.

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Figure 13.9 Worm gear
(Source: https://slideplayer.com/slide/1702897/7/images/14/Worm+Gear.jpg)

Formulas in Worm gear

1. Circular pitch
π Dg
Pc =
Ng

Where: Pc = circular pitch

Dg = gear diameter (mm or in.)
Ng = number of teeth in gear
2. Diametral pitch
Ng
Pd =
Dg

3. Lead
L = Nt P a

Where: Pa = axial pitch

L = lead (mm or in.)
Ng = number of threads

4. Lead Angle
L
λ = tan -1
πDw

Where: λ = lead angle

L = lead (mm or in.)
Dw = worm diameter (mm or in.)

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5. Pitch Line Velocity
a. For Worm
Vw = π Dw nw
b. For Gear
Vg = π Dg ng

Where: Vw = pitch line velocity of the worm (m/s or ft/s)

Vg = pitch line velocity of the gear (m/s or ft/s)
nw = rotative speed of worm (rpm or rps)
ng = rotative speed of the gear (rpm or rps)

6. Torque Transmitted by Worm

Dw
T = Wt ( ¿
2

Where: T = torque transmitted (N-m or lb-in.)

Wt = tangential force on the worm (N or lb)
7. Separating Force
Ft sinΦ n
S=
cos Φ n cos λ − fsin λ

Where: S = separating force (N or lb)

Ft = tangential force on gear (N or lb)
Φn = normal pressure angle (deg)
λ = lead angle
f = coefficient of friction
8. Tangential Force on the Worm
cos Φ n sin λ+fcos λ
Wt =Ft [ ¿
cos Φ n cos λ − fsin λ

Where: Wt = tangential force on the worm (lb)

Ft = tangential force on gear (N or lb)
Φn = normal pressure angle (deg)
λ = lead angle
f = coefficient of friction

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9. Efficiency of the Worm Gear
cos Φn − f tan λ
e = tan λ [ ]
cos Φ n tan λ+ f

Where: e = efficiency

10. Face Width

1
b= D wo
2

Where: b = face width (mm or in.)

Dwo = outside diameter of the worm (mm or in.)
11. Outside Diameter of Worm
Dwo = Dw + 2a

Where: a = addendum
Dwo = outside diameter of the worm (mm or in.)
Dw = worm diameter (mm or in.)

12. Worm Diameter

0.875
C
Dw =
2.2

Where: C = center distance (in.)

NOTE: Use this formula if center distance is given.

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 III. PROGRESS CHECK

A. Identify the correct answers to the following questions.

____________1. Circle which corresponds to section of equivalents cylinder by a plane normal

to wheel axis is known as?

____________2. The product of the diametral pitch and circular pitch is equal to?

____________3. Driving gear of two mating gear which is generally small is known as?

____________4. Ratio of circumference of pitch circle to number of teeth is known as?

____________5. Number of teeth divided by length of pitch circle diameter is known as?

____________6. The angle of which is present between line of action and common tangent to
the pitch circles?

____________7. Ratio of angular velocity of the follower to the angular velocity of driving gear
is known as?

____________8. Difference between space width and to thickness of tooth along the pitch circle
is known as?

____________9. Bottom surface of the tooth between two adjacent fillets is known as?

____________10. Tooth surface between pitch circle and the bottom land including fillet is
known as?

____________11. Angle subtended by circular pitch at the centre of pitch circle is known as?

____________12. Length of tooth parallel to gear axis is known as?

____________13. Ratio of pitch diameter in mm to the number of teeth is known as?

____________14. Type of gear which is used for power transmission in intersecting shafts.

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____________15. It is the radial distance between the working depth circle and the root circle; it
is the dedendum minus the mating addendum.

B. Problem Solving

1. A pinion gear with 22 teeth and a module of 6 mm has a rotational speed of 1200
rpm and drives a gear at 660 rpm. Determine:
i) The number of teeth on the gear, and;
ii) The theoretical centre distance
2. A gear drive consists of two gears, A and B, and has a velocity ratio of 1.50. Gear
A, the smaller of the two gears, revolves at 126 rpm in the clockwise direction,
and has 28 teeth. If the gears have a module of 2 mm, determine:
i) The number of teeth on Gear B.
ii) The pitch (reference) diameters for the two gears.
iii) The addendum.
iv) The dedendum.
v) The circular pitch.
vi) The tooth thickness.
vii) The speed of Gear B.
viii) The theoretical centre distance of the two gears.

IV. REFERENCES

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION
 Miller, Rex (2004). Audel Machine Shop Tools and Operations, Wiley
Publishing Inc.

Burghardt, H.D. et. al., (1959). Machine Tool Operation 1.

EP DeGarmo et.al. (1988). Materials &Processes in Manufacturing 7 th Edition,

Macmillan Publishing Company, New York

3G Elearning (2014). Machine Shop Operations, 3G Elearning

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for EDUCATIONAL PURPOSES ONLY and is NOT FOR SALE NOR FOR REPRODUCTION