Helical Gear 4.3.

Gear drives

Worm gear
Super gear

Bevel gears

Rack and pinion 1

 4.3. Gear Drives
Gear drives are packaged units used for a wide range of power transmission applications.

They are used to transmit power to a driven piece of machinery and to change or modify the
power that is transmitted.
Advantages of Gear Drives
1. It transmits the exact velocity ratio.
2. It is used to transmit large power.
3. It is used for small Centre distances of shafts.
4. It has high efficiency,
5. It has reliable service, and
6. It has a compact layout.
Disadvantages of Gear Drives
Since the manufacture of gears requires special tools and equipment, therefore they are
more expensive than other drives.
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 4.3. Gear Drives
Power transmission is the movement of energy from its place of generation to a location
where it is applied to performing useful work.

A gear is a component within a transmission device that transmits rotational force to another
gear or device.

TYPES OF GEARS

1) Super gear 3) Bevel gear

5) Rack and pinion
2) Helical gear 4) Worm gear

3
Power transmission is the movement of energy from its place of generation to a location
where it is applied to performing useful work.

A gear is a component within a transmission device that transmits rotational force to another
gear or device.

How Manual Transmissions Work! (Animation).mp4

TYPES OF GEARS

1) Super gear 3) Bevel gear

5) Rack and pinion
2) Helical gear 4) Worm gear
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 4.3.1. TYPES OF GEARS

1. SPUR GEAR
Teeth is parallel to axis of rotation
Transmit power from one shaft to another parallel shaft.
External and Internal spur Gear

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 4.3.1. TYPES OF GEARS

2. Helical Gear
1) The teeth on helical gears are cut at an angle to the face of the gear
2) This gradual engagement makes helical gears operate much more smoothly and quietly than
spur gears.
3) Used to transmit motion between parallel or nonparallel shafts.

6
 3. Bevel gears Cont.…
Bevel gears are useful when the direction of a shaft's rotation needs to be changed.
Usually mounted on shafts that are 90 degrees apart, but can be designed to other angles as well
The teeth on bevel gears can be straight or spiral.
Marine applications, automobiles, printing presses, cooling towers, power plants, steel plants,
railway track inspection machines, etc.

Straight and Spiral

Bevel Gears

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 4. Worm gear Cont.…

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.

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 5. Rack and pinion Cont.…
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.

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4.3.2. Nomenclature of spur gears

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 4.3.2. Nomenclature of spur gears
 Addendum: (a) is the radial distance of a tooth from the pitch circle to the top of the tooth.
 Dedendum: (b) is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
 The whole depth h 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
Working Depth: it is the radial distance from the
addendum circle to the clearance circle.
• It is equal to the sum of the addendum of the two
meshing gear
 4.3.2. Nomenclature of spur gears
 Module m: it is the ratio of the pitch diameter to the number of teeth. The customary unit of
length used is the millimetres. The module is the index of tooth size in SI
D
m=T

 Diametral pitch Pd , It is the ratio of the number of teeth on the gear to the pitch diameter. Thus,
it is the reciprocal of the module.
 Since the diametral pitch is used only with U.S. units, it is expressed as teeth per inch
T
 Pd = Where, Pd is diametral pitch, T is number of teeth and D is pitch diameter
D
Circular pitch (Pc ): The distance measured on the circumference of the pitch circle from a point of
one tooth to the corresponding point on the next tooth.
equal to the sum of the tooth thickness and the width of space.
𝜋𝐷 𝜋
Pc = = 𝜋m = and also P𝑑 × Pc = 𝜋
𝑇 Pd

Pitch circle is a theoretical circle upon which all calculations are usually based; its diameter is the pitch diameter
 4.3.2. Nomenclature of spur gears
pressure angle(φ) it usually has values of 20 or 25◦

 First determine pitch diameter from Pd , T

 And specify (locate)the center
 Then construct r1 and 𝑟2
 Draw line ab tangent to pitch point
 Draw line cd through point p by forming φ from ab.
 Line cd is called pressure line, generating line, and
the line of action.
 It represents the direction in which the resultant
force acts between the 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.
It is a theoretical circle used to generate the involute curve when creating tooth profiles. 13
4.3.2. Nomenclature of spur gears
 4.3.2. Nomenclature of spur gears
r𝑏 = r × cosφ, where r is the pitch radius
The addendum and dedendum distances for standard interchangeable teeth are.
Therefore, for the pair of gears we are constructing,
1
a=
Pd
1.25
b=
Pd

• Using these distances, draw the addendum and dedendum circles on the pinion and on the gear
as shown in Fig.
 4.3.2. Nomenclature of spur gears
 To draw a tooth, we must know the tooth thickness.
𝜋𝐷 𝜋
 The circular pitch is Pc = =
𝑇 𝑃𝑑
Pc
 Therefore, the tooth thickness = , Since tooth thickness is equal to tooth space.
2
 The portion of the tooth between the clearance circle and the dedendum circle includes the fillet.
In this instance the clearance is
c=b−a
1.25 1 0.25
c= -
Pd Pd Pd

The base pitch is related to the

circular pitch by the equation
 4.3.3. Velocity ratio of gear drive

 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 ω 2 ,
respectively.
 Then the pitch-line velocity is: V = | 𝑟1 ω1 | = | 𝑟2 ω 2 |
 Thus the relation between the radii on the angular velocities is
ω 1 r2 𝑁 𝐺
 Velocity ratio (n) = = == 1= 2
ω 2 r1 𝑁2 𝐺1

Where, d = diameter of the pitch circle, N =Speed of the gear,

ω = Angular speed , G = teeth of gear
 4.3.4. Force Analysis of Spur Gear
 Let the numeral 1 for the frame of the machine, we shall designate the input gear as gear 2, and
then number the gear successively 3, 4, etc., until we arrive at the last gear in the train.

𝐹23 = the force exerted by gear 2 on gear 3

𝐹32 = the force exerted by gear 3 on gear 2
𝐹2𝑎 = The force of gear 2 on a shaft 'a’
𝐹𝑎2 = the force of a shaft a against gear 2
𝐹𝑟 = radial directions
𝐹𝑡 = tangential directions
𝑁2 = rotation of pinion on the shaft ‘a’ in rev/min
𝑁3 = rotation of gear on the shaft ‘b’ in rev/min
𝑇𝑎2 due to 𝐹𝑎2

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 . 4.3.4. Force Analysis of Spur Gear
 The free-body diagram of the pinion has been redrawn and the
forces have been resolved into tangential and radial components.
𝑊𝑡 = 𝐹 𝑡 32
 as the transmitted load, this tangential load is really the useful
component, because the radial component 𝐹 𝑟 32 serves no useful
𝑑
purpose. It does not transmit power. T = W𝑡
2
where we have used T = 𝑇𝑎2 and d = 𝑑2 to obtain a general relation.

The power H transmitted through a rotating gear can be obtained

from the standard relationship of the product of torque T and angular
velocity 𝜔.
𝑑
H=Tω= ( W𝑡 ) ω
2
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 4.3.4. Force Analysis of Spur Gear
Gear data is often tabulated using pitch-line velocity, which is the linear velocity
𝑑
of a point on the gear at the radius of the pitch circle; thus V = ( ) ω. Converting
2
this to customary units gives
𝑁
V = πd
60
where V = pitch-line velocity, mm/s
d = gear diameter, mm
N = gear speed, rev/s
Their for the transmitted load is
60000𝐻 where Wt = transmitted load, kN
𝑊𝑡 = H = power, kW
πd𝑁
d = gear diameter, mm
n = speed, rev/min
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 Force Analysis of helical Gears
• The point of application of the forces is in the pitch plane and in the center of the gear face.
From the geometry of the figure, the three components of the total (normal) tooth force W
are

Usually Wt is given and the other forces are desired.

In this case, it is not difficult to discover that 21
 Example 1
Example 1:- Pinion 2 in Fig. runs at 1750 rev/min and transmits 2.5 kW to idler gear 3. The teeth are cut
on the 20◦full-depth system. and a gear set consists of a 16-tooth pinion driving a 40-tooth gear. The
diametral pitch is 2, and the addendum and dedendum are 1/ Pd and 1.25/ Pd , respectively.
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 6 mm larger. Compute the
new values of the pressure angle and the pitch-circle diameters if the base circles are similar with the
previous.
c. Draw a free-body diagram of gear 3 and show all the forces that act upon it

Given data
Number of teeth on pinion, 𝑇𝑝 = 𝐺𝑝 = 16
Number of teeth on idler gear, 𝑇𝐺 = 𝐺𝐺 = 40
diametral pitch, 𝑃𝑑 = 2
Addendum, a= 1/Pd , Didundum, b =1.25/Pd
Pressure angle, 𝜑n = 20
Speed, n = 1750 rev/min
Transmitted power, H = 2.5 kW 22
 Example 1
Solution
(a), P = c
𝜋𝐷
𝑇
= 𝜋m =
𝜋
Pd
=
𝜋
2
= 1.57 inch =39. 898mm
𝑇 𝑇
The pitch diameters of the pinion and gear are, respectively,(Since, 𝑃𝑑 = , d= )
𝐷 𝑃𝑑
𝑇𝑝 16 𝑇𝐺 40
𝑑𝑝 = = =8inch =203.2mm and 𝑑𝐺 = = =20inch= 508mm
𝑃𝑑 2 𝑃𝑑 2

Therefor the center distance is 𝑑𝑝 +𝑑𝐺

2
=
203.2+508
2
=355.6mm

Since the teeth were cut on the 20◦ pressure angle, the base-circle radii (𝑟𝑏 ) are found to be,
using 𝑟𝑏 = r c𝑜𝑠 ∅,
base-circle radii for pinion = r c𝑜𝑠 ∅, = 203.2/2 c𝑜𝑠 20 =95.473mm
base-circle radii for idler gear, r c𝑜𝑠 ∅, = 508/2 c𝑜𝑠 20 =238.682mm

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 Example 1

(b), Designating 𝑑𝑝, and 𝑑𝐺, as the new pitch-circle diameters, the 6 mm increase in the center
distance requires that
,
𝑑𝑝 + 𝑑𝐺,
= 355.6mm + 6 = 361.6mm …………. Eq (1)
2
,
𝑑𝑝 16
Also, the velocity ratio does not change, and hence, , = = 0.4 …………. Eq (2)
𝑑𝐺 40

Solving Eqs. (1) and (2) simultaneously yields 𝑑𝑝, =206.63mm and 𝑑𝐺, = 516.57mm
Since 𝑟𝑏 = r c𝑜𝑠 ∅, using either the pinion or gear, the new pressure angle is r is similar with the
previous.

,
∅ = cos −1
𝑟
base circle (pinion) = cos −1 95.473
=22.47
,
𝑑𝑝 /2 206.63/2
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 Example 1
(c), we find the transmitted load to be
60000𝐻 60,000(2.5)
𝑊𝑡 = = =0.134kN, since speed
π𝑑2 𝑁 𝜋203.2(1750)
is depend on pinion (input gear)
Thus, the tangential force of gear 2 on gear 3
is Ft23= 0.134, as shown in Fig. Therefore
𝐹 𝑟 23 =𝐹 𝑡 23 tan 20 = 0.134tan 20= 0.0488kN

𝐹 𝑡 23 0.134
𝐹23 = = =0.1426kN
𝑐𝑜𝑠20 𝑐𝑜𝑠20

Since gear 3 is an idler, it transmits no power (torque) to its shaft, and so the tangential reaction
of gear 4 on gear 3 is also equal to Wt.
Therefore Ft43 = 0.134, Fr43 = 0.0488kN F43 = 0.1426KN 25
 Example 1
and the directions are shown in Fig The shaft reactions in the x and y directions are

= - (-0.134 +0.0488)= 0.052kN

= -(0.0488 + 0.134) =-0.1828kN

The resultant shaft reaction is

(0.052)2 +(−0.1828)2 = 0.19kN