Gears

General
 Types of Gears
 Spur gears
 Have teeth parallel to the axis of rotation and are used to transmit
motion from one shaft to another parallel shaft.

 Of all types, the spur gear is

the simplest and, for this
reason, will be used to
develop the primary
kinematic relationships of
the tooth form.
 Types of Gears
 Helical gears
 have teeth inclined to the axis of rotation.
 Helical gears can be used for the same applications as spur gears
and, when so used, are not as noisy, because of the more gradual
engagement of the teeth during meshing.
 The inclined tooth also develops
thrust loads and bending
couples, which are not present
with spur gearing. Sometimes
helical gears are used to
transmitmotion between
nonparallel shafts.
  Types of Gears
 Bevel gears
 have teeth formed on conical surfaces and are used mostly for
transmitting motion between intersecting shafts.

 Straight-tooth bevel gears

 Spiral bevel gears: are cut so the
tooth is no longer straight, but forms
a circular arc
 Hypoid: gears are quite similar to
spiral bevel gears except that the
shafts are offset and nonintersecting.

Straight-tooth bevel gears

 Types of Gears
 Worms and worm gears
 the worm resembles a screw.
 The direction of rotation of the worm gear, also called the worm
wheel, depends upon the direction of rotation of the worm and
upon whether the worm teeth are cut right-hand or left-hand.
 Worm-gear sets are also made so that the
teeth of one or both wrap partly around
the other. Such sets are called
singleenveloping and double-enveloping
worm-gear sets.
 Worm-gear sets are mostly used when the
speed ratios of the two shafts are quite
high, say, 3 or more.
 Nomenclature
  Pitch circle:
is a theoretical circle upon which all calculations are usually based;
its diameter is the pitch diameter.

 The pitch circles of a pair of mating gears are tangent to each

other.

 The various dimensions found

in gearing are always based on
the pitch circles.

 Pinion:
is the smaller of two
mating gears. The
larger is often called
the gear.
 Circular pitch (p):
is the distance, measured on the pitch circle, from a point on one
tooth to a corresponding point on an adjacent tooth.

 Thus the circular pitch is equal to the sum of the tooth thickness
and the width of space.

 Diametric pitch
(P):
is the ratio of the
number of teeth on
the gear to the pitch
diameter (teeth per
inch).
 • P = diametric pitch, teeth per inch
• N = number of teeth
• d = pitch diameter, in
 Example:
an 18-tooth pinion
is to mesh with a
30-tooth gear and
that the diametric
pitch of the gear set
is to be 2 teeth per
inch.
 Module (m):
is the ratio of the pitch diameter to the number of teeth (index of
tooth size in SI).

m = module, mm
d = pitch diameter, mm
p = circular pitch

 Dedendum (b):  Addendum (a):

is the radial distance from is the radial distance
the bottom land to the between the top land and
pitch circle. the pitch circle.
 Whole depth (ht):
is the sum of the addendum and
the dedendum.

 clearance circle:
is a circle that is
tangent to the
addendum circle of the
mating gear.

 Clearance (c):
is the amount by which the dedendum in a given gear exceeds the
addendum of its mating gear.
 Backlash:
is the amount by which the width of a tooth space exceeds the
thickness of the engaging tooth measured on the pitch circles.
 Conjugate action
 Involute Properties Generation of an
 Flange B is attached to the cylinder involute
A.
 Around A is wrapped a cord def.
 Point b: tracing point.
 Line ac: involute curve.
 As the cord is wrapped and unwrapped
about the cylinder, point b will trace out
the involute curve ac.
 The radius of the curvature of the involute
varies continuously, being zero at point a
and a maximum at point c (be).
 line de is normal to the involute at all points of intersection and, at
the same time, is always tangent to the cylinder A.
 The circle on which the involute is generated is called the base
circle.
 Involute Properties
 Gear with fixed centers at O1 and O2 having base circles have
radii O1a and O2b, respectively.

 A cord is wound clockwise around

the base circle of gear 1, pulled
tight between points a and b, and
wound counterclockwise around
the base circle of gear 2.

 The base circles are rotated in

different directions so as to keep
the cord tight, a point g on the
cord will trace out the involutes
cd on gear 1 and ef on gear 2.
involute action
 Involute Properties
 The involutes are thus
generated simultaneously by
the tracing point.
 The point of contact moves
along the generating line.
 The generating line does not
change position, because it is
always tangent to the base
circles,
 And since the generating line is
always normal to the involutes
at the point of contact, the
requirement for uniform
motion is satisfied.
involute action
 Fundamentals
 How to construct an involute curve?
 Divide the base circle into
a number of equal parts.
 Construct radial lines
OA0, OA1, OA2, etc.
 Beginning at A1, construct
perpendiculars A1B1,
A2B2, A3B3, etc.

 Then along A1B1 lay off the distance A1A0, along A2B2 lay off
twice the distance A1A0, etc., producing points through which
the involute curve can be constructed.
 Fundamentals
 Teeth action
 When two gears are in mesh, their pitch circles roll on one
another without slipping.
 Designate the pitch radii as r1 and r2 and the angular velocities as
ω1 and ω2, respectively.
 Then the pitch-line velocity is:
 Thus the relation between the radii on the
angular velocities is:
 Example:
To design a speed reducer such that the input speed is 1800 rev/min
and the output speed is 1200 rev/min. This is a ratio of 3:2; the
gear pitch diameters would be in the same ratio (4-in pinion
driving a 6-in gear).
 Fundamentals
 Drawing teeth on a pair of mating gears

 The center
distance (O1-O2)
is the sum of the
pitch radii, in this
case:

𝒓𝟏 +𝒓𝟐 r1 and r2: pitch radios

𝟗 𝟏𝟓 V: pitch-line
= +
𝟐 𝟐 velocity
= 𝟏𝟐 𝐢𝐧
 Fundamentals
 Drawing teeth on a pair of mating gears
 So locate the pinion and gear centers O1 and O2, 12 in apart.
 Then construct the pitch circles of radii r1 and r2.
 These are tangent at
P, the pitch point.
 Next draw line ab,
the common
tangent, through
the pitch point.
 Designate gear 1 as
the driver, and
since it is rotating
counterclockwise.
 Fundamentals
 Drawing teeth on a pair of mating gears
 Draw a line cd through point P at an angle φ to the common
tangent ab.
 The line cd has three
names, all of which are
in general use. It is
called the pressure line,
the generating line, and
the line of action.
 It represents the
direction in which
the resultant force
acts between the
gears.
 Fundamentals
 Drawing teeth on a pair of mating gears

 The angle φ is
called the pressure
angle.

 It usually has
values of 20 or 25◦,
𝟏
though 14 ◦ was
𝟐
once used.
 Fundamentals
 Drawing teeth on a pair of mating gears
 Next, on each gear draw a circle tangent to the pressure line.
 These circles are the base circles. Since they are tangent to the
pressure line, the pressure angle determines their size.

 The radius of the

base circle is:

r: pitch radius
 Fundamentals
 Drawing teeth on a pair of mating gears
 Now generate an involute on each base circle.
 Fundamentals
 Drawing teeth on a pair of mating gears
 The addendum and dedendum distances for standard
interchangeable teeth are, 1/P and 1.25/P, respectively.
 Therefore, for the pair of gears we are constructing:

 Using these distances,

draw the addendum and
dedendum circles on the
pinion and on the gear
 Fundamentals
 Drawing teeth on a pair of mating gears

 Next, using heavy drawing paper, or preferably, a sheet of

0.015- to 0.020-in clear plastic, cut a template for each involute,
being careful to locate the gear centers properly with respect to
each involute.
 Fundamentals
 Drawing teeth
on a pair of
mating gears

 angle of
approach + the
angle of recess =
the angle of
action

 line ab: the line

of action.
 Fundamentals
 Drawing teeth on a pair of mating gears
 Circular pitch is:

 the tooth thickness is:

 The portion of the tooth between the clearance circle and the
dedendum circle includes the fillet.

 In this instance the clearance is:

 Imagine a rack as a spur gear having an infinitely large pitch
diameter.
 The base pitch is
related to the
circular pitch by
the equation:

Involute-toothed pinion and rack

  A pinion in mesh with an internal, or ring, gear.

 The addendum circle of the internal gear lies inside the pitch
circle.
EXAMPLE
A gear set consists of a 16-tooth pinion driving a 40-tooth gear. The
diametric pitch is 2, and the addendum and dedendum are 1/P and
1.25/P, respectively. The gears are cut using a pressure angle of 20◦.
(a) Compute the circular pitch, the center distance, and the radii of
the base circles.
(b) In mounting these gears, the center distance was incorrectly
made 0.25 in larger. Compute the new values of the pressure
angle and the pitch-circle diameters.
 Contact Ratio

 Interference

 The Forming of Gear Teeth:

• Milling
• Shaping
• Hobbing
• Finishing
Tooth Systems
 A tooth system is a standard that specifies the relationships
involving addendum, dedendum, working depth, tooth thickness,
and pressure angle.
Standard and Commonly Used Tooth Systems for Spur Gears

The resulting gears had to be comparatively larger to avoid interference problems.

Tooth Sizes in General Uses
Tooth Proportions for 20° Straight Bevel-Gear Teeth
Standard Tooth Proportions for Helical Gears
Recommended Pressure Angles and Tooth Depths for Worm
Gearing
Gear Trains

nL: the speed of the last gear in the train

e: Train value
nF: the speed of the first gear in the train
 Example:
 A gearbox is needed to provide a 30:1 (1 percent) increase in
speed, while minimizing the overall gearbox size. Specify
appropriate teeth numbers.
 Since the ratio is greater than 10:1, but less than 100:1, a two-
stage compound gear train is needed.
 The portion to be accomplished in each stage is √30 = 5.4772.
 For this ratio, assuming a typical 20° pressure angle, the
minimum number of teeth to avoid interference is 16. The number
of teeth necessary for the mating gears is:

The overall train value is

This is within the 1 percent tolerance. If a closer tolerance is
desired, then increase the pinion size to the next integer and try
again.
 Example:
 A gearbox is needed to provide an exact 30:1 increase in speed,
while minimizing the overall gearbox size. Specify appropriate
teeth numbers.
 Example:
 A gearbox is needed to provide an exact 30:1 increase in speed,
while minimizing the overall gearbox size. The input and output
shafts should be in-line. Specify appropriate teeth numbers.
 planetary gear train (epicyclic gear train )

nF = rev/min of first gear in planetary train

nL = rev/min of last gear in planetary train
nA = rev/min of arm
 Example:
 A sun gear is the input, and it
is driven clockwise at 100
rev/min. The ring gear is held
stationary by being fastened to
the frame. Find the rev/min
and direction of rotation of the
arm and gear 4.

 Designate nF = n2 = -100
rev/min, and nL = n5 = 0.
Unlocking gear 5 and
holding the arm stationary:
Force Analysis-Spur Gearing
 Gears
Spur and Helical Gears
 The Lewis Bending Equation
 Assume that the maximum stress in a
gear tooth occurs at point a.

P= circular pitch
 The Lewis Bending Equation

• y = Lewis form factor

 If:
P = π/p and Y = πy
Values of the Lewis Form Factor Y, for a normal pressure
angle of 20°, full-depth teeth.
 Dynamic Effects
 Carl G. Barth first expressed the velocity factor (for
Cycloidal teeth):

Barth equation

Modified Barth
equation
• V = the pitch-line velocity, ft/min

 AGMA standards
(for involute teeth):
 Dynamic Effects
 In SI units:

• V = the pitch-line velocity, m/s

 Introducing the velocity factor into the Lewis
Bending equation:

 The metric version of this equation is:

EXAMPLE
A stock spur gear is available having a diametral pitch of 8
teeth/in, a 11 2 -in face, 16 teeth, and a pressure angle of 20◦ with
full-depth teeth. The material is AISI 1020 steel in as-rolled
condition. Use a design factor of nd = 3 to rate the horsepower
output of the gear corresponding to a speed of 1200 rev/m and
moderate applications (from table A-20: Sut = 55 kpsi and Sy =
30 kpsi.).

 The term moderate applications seems to imply that the gear

can be rated by using the yield strength as a criterion of
failure.
 A design factor of 3 means that the allowable bending stress is
30/3 = 10 kpsi. The pitch diameter is N/P = 16/8 = 2 in,
EXAMPLE
Estimate the horsepower rating of the gear in the previous
example based on obtaining an infinite life in bending.