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The document discusses power transmission through gears, focusing on friction gearing and various types of gears including spur, helical, bevel, and worm gears. It explains the mechanics of gear interaction, including torque, speed ratios, and contact ratios, emphasizing the importance of proper gear meshing for efficient operation. Additionally, it covers the classification of gear trains and their applications in mechanical systems.

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0% found this document useful (0 votes)
12 views40 pages

Screenshot 2025-04-19 at 8.42.24 AM

The document discusses power transmission through gears, focusing on friction gearing and various types of gears including spur, helical, bevel, and worm gears. It explains the mechanics of gear interaction, including torque, speed ratios, and contact ratios, emphasizing the importance of proper gear meshing for efficient operation. Additionally, it covers the classification of gear trains and their applications in mechanical systems.

Uploaded by

TâhmîdTZ
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Mechanisms & Machine

Design
Gears
Introduction
• 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
Friction Gearing
A simple means of transmitting rotational motion and
power from one shaft to another is pair of friction
gears, as shown in Figure 5.1(a). Here, transmission
relies on the friction force between the cylinders in
contact.

The free body diagram of each cylinder is shown in


Figure5.1(b). Tangent to both cylinders is a force of
magnitude. F= F (5.2-1)
In the arrangement shown, gear 2 is the
driver gear. and gear 3 is the driven gear.
Power is supplied to the system through the
shaft connected to gear 2, and power is
removed from the system through the shaft
attached to gear 3. The torque of driving
gear 2 is in the same direction as its
rotational speed.
T2 = Fr2 (5.2-2)
Figure 5.1 Friction gears: (a) friction gear set,
(b) free body diagrams.
Friction Gearing
The torque applied to driving gear 3 is in the opposite direction to its rotation.

T3 = Fr3 (5.2-3)
Combining Eq. (5.2-2) and (5.2-3)
T2 Fr r
= 2 = 2 (5.2-4)
T3 Fr3 r3

If no slip, r2 2 = r3 3 (5.2-5)
3 r2
 = (5.2-6)
2 r3

Combining Eq. (5.2-4) and (5.2-6)


T22 = T33 (5.2-7)

However, multiplication of a torque by a rotational speed yields power. Therefore,


Equation (5.2-7) states that assuming no slippage between the friction gears, no
power is lost in the transmission.
Friction Gearing
One definite advantage of using friction gearing is
the ease of generating a continuous range of speed
ratios. Consider the system shown in Figure 5.2.
Changes in speed ratio are accomplished by altering
the orientation of the idler wheel, link 3, and thereby
varying the radii of contact between links 2 and 4. In
the illustration, three positions of the idler wheel are
shown that produce three distinct speed ratios. If the
input cone 2 rotates at a constant rate, then the
output of cone 4 may have a varying rotational
speed.

Figure 5.2 Continuously variable traction drive.


Friction Gearing
Figure 5.3 shows an alternative system that can produce a continuous range of
speed ratios. This system employs a variation of the open loop friction drive.

Figure 5.3 Continuously variable belt drive: (a) high speed ratio, (b) low speed ratio.
Gear Assembly
For two gears to mesh properly and work
together smoothly, they must have the
same:
1.Diametral Pitch
2.Circular Pitch
3.Module
Type of Gears
According to the position of axes of the shafts.
a. Parallel
1. Spur Gear
2. Helical Gear
3. Rack and Pinion
b. Intersecting
Bevel Gear
c. Non-intersecting and Non-parallel
Worm and worm gears
Spur Gear
• Teeth is parallel to axis of rotation
• Transmit power from one shaft to
another parallel shaft
• Used in Electric screwdriver,
oscillating sprinkler, windup alarm
clock, washing machine and
clothes dryer.
External and Internal Spur Gear
Helical Gear
• The teeth on helical gears are cut
at an angle to the face of the gear
• This gradual engagement makes
helical gears operate much more
smoothly and quietly than spur
gears
• One interesting thing about helical
gears is that if the angles of the
gear teeth are correct, they can be
mounted on perpendicular shafts,
adjusting the rotation angle by 90
degrees
Herringbone Gears
• To avoid axial thrust, two
helical gears of opposite hand
can be mounted side by side,
to cancel resulting thrust
forces

• Herringbone gears are mostly


used on heavy machinery.
Rack and Pinion
• 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
Bevel Gears
• Bevel gears are useful when the direction of a shaft's
rotation needs to be changed
• They are usually mounted on shafts that are 90
degrees apart, but can be designed to work at other
angles as well
• The teeth on bevel gears can be straight, spiral or
hypoid
• locomotives, marine applications, automobiles, printing
presses, cooling towers, power plants, steel plants,
railway track inspection machines, etc.
Straight and Spiral Bevel Gears
Worm and Worm Gear
• 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
Nomenclature of Spur Gears

Figure 5.28 Spur gear terminology: (a) external gear, (b) rack, (c) internal gear.
Nomenclature of Spur Gears
• Pitch surface: The surface of the imaginary rolling cylinder
(cone, etc.) that the toothed gear may be considered to
replace.
• Pitch circle: A right section of the pitch surface.
• Addendum circle: A circle bounding the ends of the teeth,
in a right section of the gear.
• Root (or dedendum) circle: The circle bounding the
spaces between the teeth, in a right section of the gear.
• Addendum: The radial distance between the pitch circle and
the addendum circle.
• Dedendum: The radial distance between the pitch circle and
the root circle.
• Clearance: The difference between the dedendum of one
gear and the addendum of the mating gear.
Nomenclature of Spur Gears
• Face of a tooth: That part of the tooth surface lying
outside the pitch surface.
• Flank of a tooth: The part of the tooth surface lying
inside the pitch surface.
• Circular thickness (also called the tooth thickness):
The thickness of the tooth measured on the pitch circle.
It is the length of an arc and not the length of a straight
line.
• Tooth space: The distance between adjacent teeth
measured on the pitch circle.
• Backlash: The difference between the tooth thickness
of one gear and the tooth space of the mating gear.
• Circular pitch (Pc) : The width of a tooth and a space,
measured on the pitch circle.
D 2r
Pc = =
N N
Nomenclature of Spur Gears
• Diametral pitch (Pd): The number of teeth of a gear unit
pitch diameter. The diametral pitch is, by definition, the
number of teeth divided by the pitch diameter. That is,
N N
Pd = =
D 2r

where, Pd = diametral pitch; N = number of teeth; D = pitch


Diameter
Pc Pd = 

• Module (m): Pitch diameter divided by number of teeth. The


pitch diameter is usually specified in inches or millimeters; in
the former case the module is the inverse of diametral pitch.
D 2r
m= =  D = 2r = mN
N N
Standard Proportions of Gear Teeth as a
Function of Diametral Pitch
Examples
Examples
Contact Ratio
In the transmission of rotational motion through two meshing gears, it is essential that
at any time one or more pairs of teeth be in contact. Otherwise, there would be
instances when there is no smooth transfer of motion. Driver
For a pair of meshing gears turning at a constant rate,
Contact ratio is the average number of pairs of
gear teeth in contact over time. Theoretically, the Driven
value of contact ratio must be greater than 1.00.
However, 1.40 is generally accepted as the Driver
practical minimum value.
Initial contact, labeled as point A in Figure 5.34(a),
occurs when the outer tip of the driven gear tooth
Driven
touches the driver gear. Final contact, labeled as point
B in Figure 5.34(c), occurs when the outer tip of the Driver
driver gear tooth contacts the driven gear. For both of
these configurations there is a second pair of teeth in
contact. Thus, prior to and after the noted teeth come Driven
into and out of mesh, there is another pair of teeth in
mesh, which ensures continuous and uniform Figure 5.34 Two spur gears in mesh: (a)
initial ontact, (b) contact at pitch point, (c)
transmission of motion. final contact.
Contact Ratio
At any instant in time, there is an integer number
of pairs of gear teeth in mesh. For the gears
shown in Figure 5.34, during a portion of the
cycle, one pair of gear teeth is in mesh, where as
at other times there are two pairs. Figure 5.35
shows the function of the number of pairs of gear
teeth in mesh over time for the gear set
illustrated in Figure 5.34. The time average of the
curve, which is the contact ratio, is
0.53 0.47

1 0.47 + 2  0.53
mc = = 1.53 

Figure 5.35 Example of contact ratio.


Speed Ratio
The speed ratio of component with respect to component i in a gear train is
defined as,
rotational speed of component j
e j /i = (6.1-1)
rotational speed of component i
Positive ej/i values indicate that components j and i
both turn in the same direction. Negative ej/i values
signify an opposite direction of rotation. Equation
(6.1-1) may be applied to the overall speed ratio of
the gear train. In that instance, j corresponds to the
output component of the gear train, and i
corresponds to the input component.

For the external-external meshing pair shown in


Figure 6.2(a), the gears rotate in opposite directions,
and the speed ratio is negative. For the external-
internal pair, Figure 6.2(b). the gears rotate in the
same direction. and the speed ratio is positive.
Figure 6.2 Meshing gears represented by
their pitch circles: (a) external-external pair,
(b) external-internal pair.
Speed Ratio
For cases where the axes of rotation are not parallel, such as with worm and
wheel, miter. and bevel gears, only the magnitude of the speed ratio is defined
by Equation (6.1-1), and the direction of rotation may be determined using a
suitably prepared sketch.

As the number of teeth on a gear is proportional to its pitch circle diameter.


Gears in mesh must be of the same pitch and the magnitude of the speed
ratio of a pair of meshing gears is inversely proportional to the ratio of the
radii. Thus, we conclude that the magnitude of the speed ratio is inversely
proportional to the ratio the number of gear teeth. Figure 6.2(a), having N2
and N3 teeth on gears 2 and 3, respectively,
3 N
e3 / 2 = =− 2 (6.1-2)
2 N3
Figure 6.2(b), having N2 and N3 teeth on gears 2 and 3, respectively,

Output N Input 3 N
eOutput/ Input = = e3 / 2 = =+ 2 (6.1-3)
 Input N Output 2 N3
Classification of Gear Trains

Speed ratios for meshing gears 2 and 3 and


gears 4 and 5 are

N2 N4
e3 / 2 = − e5 / 4 = −
N3 N5

The speed ratio for the gear train is, 2


1 4
 N 2  N 3  N 4 
e5 / 2 =  −  −  − 
3 trains with the
 N 3  N 4  N 5  Figure 6.3 Two simple gear
same speed ratio.
Classification of Gear Trains
In this instance, unlike the case of simple gear
trains, the numbers of teeth of the idler gears
influence the magnitude of the speed ratio.
Using a similar analysis, the speed ratio for the
compound gear train in Figure 6.6(b) is

N2 N4 N
e3 / 2 = − e5 / 4 = − e6 / 5 = − 4
N3 N5 N5
 N 2  N 4  N 5  N N
e6 / 2 = e3 / 2 e5 / 4 e6 / 5 =  −  −  − =− 2 4 Figure 6.6 Compound gear trains
 N 3  N 5  N 6  N3 N6

Idler gear 5 has no effect on the magnitude of the speed ratio; although it
affects the direction of output speed and the distance between the input and
output shafts.
Classification of Gear Trains
The compound gear train illustrated in Figure
6.6(c) incorporates an external-internal
meshing pair. The numbers of teeth are
N2 = 9; N3= 62; N4 = 20;
N5 = 51; N6 = 15; N7= 54
 N 2  N 4  N 6 
e7 / 2 = e3 / 2 e5 / 4 e7 / 6 =  −  −  
 N 3  N 5  N 7 
9  20 15
= = 0.0158 = 1:63.3 Figure 6.6 Compound gear trains

62  51 54
This arrangement of gears is employed in the
design of a winch. Figure 6.7 shows a
corresponding photograph of the system.
A compound gear train may be designed to
provide multiple speed ratios through one
output shaft by transmitting motion through
various pairs of gears.
Figure 6.7 Gear train used in a winch
Example 6.1 Speed Ratios for Manual
Transmission
Figure 6.8 shows a schematic of a manual
transmission, which employs a compound
gear train. The Shifter allows pairs of
gears to be disengaged and reengaged to
obtain three different speed ratios.
Determine the speed ratios of the gear
train.
Solution: Figure 6.8 Compound gear trains

O/P Gears in Mesh Speed Ratio


Speed
1 1,2,7,8 N1 N 7
e8 /1 =
N 2 N8
2 3,4,7,8 N3 N7
e8 / 3 =
N 4 N8
3 5,6,7,8 N5N7
e8 / 5 =
N 6 N8
Example
Fig. shows a gear train mechanism. Determine the velocity
of Gear 8 if the input gear 2 rotates at 1200 rpm
counterclockwise.
Example 6.2 Design for the Number of
Teeth of a Reverted Gear Train
Find the tooth numbers for the gear train shown in Figure 6.8, to generate the speed
ratios 1/4.00; 1/2.45 and 1/1.55. All gears are to have at least 12 teeth. The center-
to-center distance between the idler and input/output shafts is 72 mm, and all gears
have a module of 4mm.
Solution:
Because all gears are to have the same module, and meshing gears must share a
common center to center distance, then for a pair of meshing gears,
N1 N 7 N3 N7 N5N7
e8 /1 = e8 / 3 = e8 / 5 =
N 2 N8 N 4 N8 N 6 N8
di d j 1
= (d i + d j ) = (N i + N j )
m
Ci , j = +
2 2 2 2
 Ci , j = (N i + N j )  72 = (N i + N j )
m 4
2 2
 (N i + N j ) = 36

 (N1 + N 2 ) = (N3 + N 4 ) = (N5 + N 6 ) = (N 7 + N8 ) = 36


Figure 6.8 Compound gear trains
Example 6.2 Design for the Number of
Teeth of a Reverted Gear Train
The first desired speed ratio, e8 /1 = 1 / 4.00 can match exactly considering,

N N N 7 = 12; N 8 = 24;
e8 /1 = 1 7 As, 4=2x2 by factorization
N 2 N8 N1 = 12; N 2 = 24;

The second and third desired speed ratio, e8 / 3 = 1 / 2.45 and e8 / 5 = 1 / 1.55 can not match
exactly considering, by trial & error
N N
e8 / 3 = 3 7 = 1 / 2.45 (N 3 + N 4 ) = 36
N 4 N8
N 3 N 7 16 12
N 3 = 16; N 4 = 20; = = 1 : 2.50
N 4 N 8 20  24

N5N7
e8 / 5 =
N 6 N8
= 1 / 1.55 (N 5 + N 6 ) = 36

N 5 = 20; N 6 = 16; N 5 N 7 20 12


= = 1 : 1.60
N 6 N 8 16  24
Figure 6.8 Compound gear trains
Example 6.2 Design for the Number of
Teeth of a Reverted Gear Train
Values closest to the desired speed ratio, satisfying the constraints for the minimum
number of teeth on a gear,
N1 = 12; N 2 = 24; e8 /1 = 3.54
N 3 = 15; N 4 = 21; e8 / 3 = 2.48
N 7 = 19; N 8 = 17; e8 / 5 = 1.58

Figure 6.8 Compound gear trains


Gear Trains Design Constraints
1. For a particular gear train, all meshing gear must have the
same module or diametral pitch.
2. Maximum allowed train ratio is 10:1
3. If desired train ratio is greater than 10:1 then factorize the
train ratio by root or factorizing method such that individual
train ration is less than 10:1
4. The number of roots or factors represents the number of
pairs of gears i.e. number of stages in the desired gear train.
5. The minimum number of teeth is 12- 17, but 14- 17 is better.
Gear Trains Design Example
Design a compound gear train for an exact train ratio of 180:1. Find a combination of
gears which will give that ratio.
2 180
Solution: As desired gear ratio>10, thus number of stages are,
2 90
180 = 13.41 not satisfied. 3 45
3
180 = 5.646 whis is less than 10 , thus satisfied. 3 15
5
Therefore, number of stages are 3.
Possible Gear sets for 180:1 180 = ( 3  2 )( 3  2 )( 5 ) = 6  6  5
speed reduction of three
stages gear train Possible Gear sets for 180:1
speed reduction of three
Gearset Pinion Gear Teeth
stages gear train
Ratio Teeth
Gearset Pinion Gear Teeth
5.646 x 12 67.7568
Ratio Teeth
5.646 x 13 73.3973
6 x 14 84
5.646 x 14 79.0479
6 x 14 84
5.646 x 15 84.6985
5 x 14 70
Gear Trains with Bavel Gear
Gear trains with bevel gears, hypoid gears and worm and gear sets have
nonparallel axes of rotation. The magnitude of the speed ratio between any two bevel
gears in mesh is inversely proportional to their number of gear teeth.
3 N 2 4 N 3
e3 / 2 = = e4 / 3 = = (6.2-10)
2 N 3 3 N 4

The magnitude of the speed ratio of the gear train is,


   I/P Gear
O/P Gear
e4 / 2 = e4 / 3  e3 / 2 = 4 3 = 4 (6.2-11)
3  2  2
N3 N 2 N
e4 / 2 = e4 / 3  e3 / 2 = − =− 2 (6.2-12)
N 4 N3 N4
Idler
Gear

Figure 6.11 Gear train incorporating


bevel gears.
Example
Design a compound gear train
with a train ratio of 120:1. The
diameter of the pinion gear is 42
mm and the module is 3.

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