TOM(BME503)

BY
PROF NAGARAJU B P
VVIT, BENGALURU-77
 MODULE -3
Spur Gears: Gear terminology, law of gearing, path of contact, arc of
contact, contact ratio of spur gear. Interference in involute gears,
methods of avoiding interference, condition and expressions for
minimum number of teeth to avoid interference.
Gear Trains: Simple gear trains, compound gear trains. Epicyclic gear
trains: Algebraic and tabular methods of finding velocity ratio of epicyclic
gear trains, torque calculation in epicyclic gear trains. Discussions on
applications of gear trains.
INTRODUCTION
A gear may be defined as any toothed member designed to transmit or
receive motion from another member by successively engaging tooth.
The smaller gear is called the pinion and the bigger one the gear wheel.
They are used in metal cutting machine tools, automobiles, tractors,
hoisting and trans porting machinery, rolling mills, etc.
The gears provide many advantages over other modes of power transmission
likes belts, ropes, and chains etc. Some of their advantages are:
1. They occupy lesser space.
2. There is no slip between the gears in mesh and provide exact speed ratio.
3. They can transmit higher power.
4. Their efficiency is higher.
However, the error in tooth meshing may cause undesirable vibration and
noise during operation
CLASSIFICATION OF GEARS
GEAR TERMINOLOGY
Path of contact: It is the locus of the point of contact of two mating
teeth from the beginning of engagement to the end of engagement. It
is a straight line.
Path of approach: It is the portion of the path of contact from the
beginning of engagement to the pitch point
Angle of approach: The angle turned by gears during path of approach.
Path of recess: It is the portion of the path of contact from the pitch
point to the end of engagement of the two mating teeth.
Angle of recess: The angle turned through during path of recess.
Arc of contact: It is the locus of a point on the pitch circle, from the
beginning of engagement to the end of engagement of pair of teeth in
mesh.
FUNDAMENTAL LAW OF
GEARING
SLIDING VELOCITY BETWEEN GEAR TEETH
Comparison between Involute and Cycloidal
Tooth Profiles
INVOLUTE GEAR TOOTH ACTION
The gear tooth action between two gears is shown in Fig.14.9. P is the pitch point and
line EF is tangent to both the base circles, along which all points of contact of two
teeth must lie. Line EF is called the line of action or the pressure line. Line XX is
perpendicular to the line of centers at the pitch point. The angle between XX and EF is
called the pressure angle. If one gear rotates in clockwise direction then the other
gear would rotate in the reverse direction of counter clockwise
The teeth first come into contact at point A, where the addendum circle of the driven
gear cuts the line of action. Contact follows the line of action through point P, and
contact ceases at point B, where the addendum circle of the driving gear cuts the line
of action. Line AB is called the path of the point of contact, and its length is the length
of the path of contact. Point C is the intersection of the tooth profile on gear 2 with its
pitch circle when the tooth is at the beginning of contact, and point G is the same
point on the profile when the tooth is at the end of contact. Points D and H are the
corresponding for gear 1. Arcs CPG and DPH are the arcs on the pitch circles through
which the mating tooth profiles move as they pass from the initial to the final point of
contact. These arcs action as the arcs of action.
Since the pitch circles roll on one another, these are equal. The angles 1
and 2 which subtend these arcs are called the angles of action. The
angles of action are divided into two parts called the angle of approach
( ) and angle of recess ( ). The angle of approach is defined as the
angle through which a gear rotates from the instant a pair of teeth
comes into contact until the teeth are in contact at the pitch point. The
angle of recess is the angle through which a gear rotates from the
instant the teeth are in contact at the pitch point contact is broken. In
general, the angle of approach is not equal to the angle of recess. Gear
tooth action is smoother in recess than in approach. From Fig.14.10, we
have
CHARACTERISTICS OF INVOLUTE
ACTION
The characteristics of the involute action are:
1. arc of contact,
2. length of path of contact, and
3. the contact ratio.
As shown in Fig.14.11, the contact of two gear teeth begins at A and
ends at B.
Ex: Two equal size spur gears in mesh have 36 number of teeth, 20°
pressure angle and 6 mm module. If the arc of contact is 1.8 times the
circular pitch, find the addendum.
Ex: Two 20° involute gears in mesh have a gear ratio of 2 and 20 teeth
on the pinion. The module is 5 mm and the pitch line speed is 1.5 m/s.
Assuming addendum to be equal to one module, find (a) angle turned
through by pinion when one pair of teeth is in mesh, and (b) maximum
velocity of sliding.
Ex: The pressure angle of two gears in mesh is 20° and have a module of
10 mm. The number of teeth on pinion are 24 and on gear 60. The
addendum of pinion and gear is same and equal to one module. Deter
mine (a) the number of pairs of teeth in contact, (b) the angle of action of
pinion and gear, and (c) the ratio of sliding to rolling velocity at the
beginning of contact, at pitch point and at the end of contact
Ex: Two 15 mm module, 20° pressure angle spur gears have addendum equal to one module. The
pinion has 25 teeth and the gear 50 teeth. Determine whether interference will occur or not. If it
occurs, to what value should the pressure angle be changed to eliminate interference.
Ex: For a pair of involute spur gears, m 10 mm, =20°, z₁ =20, z₂= 40, n₁= 60 rpm. The
addendum on each gear is such that the path of approach and the path of recess
on each side is 50% of the maxi mum possible length. Determine the addendum for
the pinion and the gear and the length of arc of contact.
=
Ex: Two involute gear wheels having module 3 mm and pressure angle 20° mesh
externally to give a velocity ratio of 3. The pinion rotates at 75 rpm and addendum
is equal to one module. Determine (a) the number of teeth on each wheel so that
interference is just avoided, (b) the length of path and arc of contact, (c) the
number of pairs of teeth in contact, and (d) the maximum velocity of sliding
between the teeth.
INTERFERENCE AND UNDERCUTTING IN INVOLUTE
GEAR TEETH
An involute starts at the base circle and is generated outwards.
It is therefore impossible to have an involute inside the base circle.
The line of action is tangent to the two base circles of a pair of gears in
mesh, and these two points represent the extreme limits of the length of
action.
These two points are called interference points.
If the teeth are of such proportion that the beginning of contact occurs
before the interference point is met, then the involute portion of the
driven gear will mate with a non-involute portion of the driving gear, and
involute interference is said to occur.
This condition is shown in Fig.14.12; E₁ and E₂ show the interference points
that should limit the length of action. A shows the beginning of contact,
and B shows the end of contact. It can be seen that the beginning of
contact occurs before the interference point E₁ is met; therefore,
interference is present. The tip of the driven tooth will gauge out or
undercut the flank of the driving tooth as shown by the dotted line.
There are several ways of eliminating interference. Interference can be
avoided by under cutting, making stub teeth, increasing the pressure angle,
and cutting the gears with long and short addendum gear teeth.
The method of undercutting is to limit addendum of the driven gear so that
it passes through the interference point E₁ , thus giving a new beginning of
contact. Interference and the resulting undercutting not only weaken the
pinion tooth but may also remove and small portion of the involute
adjacent to the base circle, which may cause a serious reduction in the
length of action.
Fig.14.13 shows a rack and a pinion in mesh.
The point of tangency of the line of action and the base circle of the
pinion is labelled as the interference point E, which fixes the maximum
addendum for the rack.
The contact begins at A, and undercutting will occur as shown by the
dotted line. If the addendum of the rack extends only to the line that
passes through the interference point, E, then the interference point
becomes the beginning of contact, and interference is eliminated.
If the number of teeth on the pinion is such that it will mesh without
interference, it will mesh without interference with any other gear
having the same or a larger number of teeth
MINIMUM NUMBER OF TEETH -
Gear Wheel
• Pinion
Rack and Pinion
GEAR STANDARDIZATION
EFFECT OF CENTRE DISTANCE VARIATION ON VELOCITY RATIO
DETERMINATION OF BACKLASH
INTERNAL SPUR GEARS
A pair of involute spur gears with 16° pressure angle and pitch in module 6 mm is in mesh. The
number of teeth on pinion is 16 and its speed is 260 rpm. When the gear ratio is 1.8, find in order
that the interference is just avoided, (i) the addenda on pinion and the gear wheel, (ii) the length of
path of contact (iii) the maximum velocity sliding of teeth on either side of the pitch point.
 GEAR TRAINS
A gear train is composed of two or more gears in mesh for the purpose of transmitting motion from
one shaft to another. A gear train enables to have larger centre distance between the driving and
driven shafts, provides control on the direction of rotation of the driven gear, and facilitates
increased transmission ratio with gears of smaller sizes in a lesser space.
TYPES OF GEAR TRAINS : There are four types of gear trains:
1. Simple gear train
2. Compound gear train
3. Reverted gear train
4. Planetary (or epicyclic) gear train.
2. Simple Gear Train: A simple gear train is one in which there is only one gear on each shaft. A
simple gear train is often used to change the direction of rotation of a gear without changing its
angular velocity. This can be done by placing an idler gear between the driving and driven
gears. Consider the simple gear train shown in Fig.15.1
=
Therefore, the velocity ratio of a simple gear train is the ratio of the angular velocity of the first gear
in the train to the angular velocity of the last gear. We find that the intermediate gears do not in any
way affect the velocity ratio. These gears are called idler gears. If the number of gears in the train
are even then the direction of rotation of the last gear is reversed and if the number of gears in the
train are odd then the direction of rotation of the last gear remains the same. Idler gears are used
for two purposes: to connect gears where a large centre distance is required, and to control the
directional relationship between gears.
2. Compound Gear Train: A pair of gears is compound if they have a common axis and are integral.
A compound gear train is a gear train containing compound gears. Consider the compound gear
train shown in Fig.15.2. Gears 2 and 3 are on the same shaft.
The ratio given by Eq.(15.2) is called the train value.
3. Reverted Gear Train: In a reverted gear train the first and the last
gear are coaxial (same axis). Reverted gear trains are used in
automotive transmission, lathe back gears, industrial speed reducers,
and in clocks where the minute and hour hand shafts are coaxial.
In the reverted gear train shown in Fig.15.3, we have Centre distance,
C=+ = +
For same module (m =d/z) of all gears, the pitch radius of gears is
proportional to the number C= ++
4. Planetary Gear Trains: These are gear trains in which the axis of one
or more gears move relative to the frame. The gear at the centre is
called the sun, and the gears whose axes move are called the planets.
In Fig.15.4, arm 3 drives gear 1 about gear 2, which is a fixed external
gear. Gear 1 rotates about its centre d while this centre rotates about
centre O2 of the fixed gear. As gear 1 rolls on the outside of gear 2, a
point on its surface will generate an epicycloid. If gear 2 happens to be
an internal gear and gear 1 rolls on the inside of gear 2, then a point on
the surface of gear 1 will generate a hypocycloid. Because of the curves
generated, a planetary gear train is often called as an epicyclic, or
cyclic, gear train.
DETERMINATION OF SPEED RATIO OF PLANETARY GEAR TRAINS
TORQUE IN EPICYCLIC GEAR TRAINS
Consider the rotating parts of an epicyclic gear train shown in Fig.15.7.
if the rotating parts have no angular acceleration, then the gear train is
kept in equilibrium by the following three externally applied torques:
1. Input torque (T1 ) on the driving member.
2. Output torque (T2 ) on the driven member.
3. Braking torque (T3 ) on the fixed member.
The net torque applied on the gear train must be zero, i.e.

If F₁ , F₂ , and F₃ are the externally applied forces at radii r₁ , r₂ , and r₃ ,

then
In a reverted epicyclic gear train, the arm A carries two gears 1 and 2 at
centre of rotation O1 and a com pound gear 3 and 4 at centre of
rotation O₁. The gear 1 meshes with gear 4 and the gear 2 meshes with
gear 3. The number of teeth are: z₁ =75, z₂ =30, and z₃= 90. Find the
speed and direction of gear 2 when gear 1 is fixed and the arm A makes
120 rpm clockwise. Assume all gears to be of the same module.
r₁ + r₄ =r₂+ r₃ or z₁+ z₄= z₂ +z₃
z₄ =30 +90 -75= 45
An epicyclic gear train consists of three gears 1, 2 and 3 as shown in Fig.15.8. The internal gear 1 has
72 teeth and gear 3 has 32 teeth. The gear 2 meshes with both gear 1 and gear 3 and is carried on
an arm A which rotates about the centre O₂ at 20 rpm. If the gear 1 is fixed, determine the speed of
gears 2 and 3.
An epicyclic gear train consists of a sun wheel S, a stationary annular wheel E and three identical
planet wheels P carried on a star-shaped carrier C, as shown in Fig.15.14. The size of different
toothed wheels is such that the planet carrier C rotates at 1/5 th of the speed of the sun wheel S.
The minimum number of teeth on any wheel is 18. The driving torque on the sun wheel is 120 Nm.
Determine (a) the number of teeth on different wheels of the train, and (b) the torque necessary to
keep the internal gear stationary.