Lecture - 11 & 12
Lecture - 11 & 12
Lecture 11
Gear Trains
All figures taken from Design of Machinery, 6th ed. Robert Norton
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Gears & Their Types
• Gears: Gears are attained, when meshing teeth are added to the rolling
cylinders to prevent slip.
• Gearset: Combination of gears that mesh to provide a particular gear ratio.
• In any gearset:
• Smaller of two gears is called pinion
• Remaining is called Gear
• Types: Internal & External gears
• External gears rotate in opposite directions
• Internal gears rotate in same direction
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Fundamental Law of Gearing
• The angular velocity ratio between 2 meshing gears remains constant throughout the mesh
• Angular velocity ratio (mV) and Torque ratio (mT) of Gearset is given by equation:
v = ωr
In equations 9.1, negative sign will be used for external gears as ωin rin = ωout rout
direction of rotation is reversed & vice versa.
𝟏
Mathematically, 𝒎𝑻 =
𝒎𝒗
• Gearset transfers rotational motion, in which only torques act on gears (applied forces = 0).
• It exchanges torque at the expense of velocity or vice versa
• Common Application of Gearset: Automobile Transmission, in which:
• Velocity is reduced & torque is increased to drive heavy loads.
• Velocity is increased by reducing torque.
⇨ Generally a high speed rotating shaft has small torque associated with it. Gearsets are used to reduce
speed and increase the torque.
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Involute Tooth Shape
• Fundamental law of gearing remain applicable, if shape
profile of two nearby teeth are conjugate pairs.
• For this purpose, most of gears use the involute curve for
their shape
• Involute curve is the shape obtained by unwrapping a string
from around a circle or cylinder
• The cylinders from which the strings are unwrapped are called
the base circles of the respective gears.
• Allows the fundamental law of gearing to be followed even if
center distance is not maintained
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Meshing Action
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Contact Geometry
Pressure angle (): Angle between force and motion
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Fundamental Law of Gearing
The common normal of the tooth profiles, at all contact points within the mesh, must always pass
through a fixed point on the line of centers, called the Pitch point
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Change in Center Distance
• By using involute tooth form, the
fundamental law of gearing
remain applicable, even if the
center distance changes
• With an involute tooth form,
center distance errors do not
affect the velocity ratio.
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Backlash
• Backlash – the clearance between mating teeth measured at the pitch circle
• Backlash not become a problem when gearset runs with a non-reversing torque.
• Whenever torque changes sign,
• teeth will move from one side of contact to another
• backlash gap will be traversed,
• Teeth will impact with noticeable noise.
• Backlash increases with increase in center distance
• Backlash causes undesirable positional error with the increase of stresses and wear.
• Solution: Anti-backlash gears - two back to back gears are mounted on the same shaft, which will
rotate slightly w.r.t one another, and then fixed to take up the backlash.
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Gear Tooth Nomenclature
Putting equations 9.4b and then 9.4d into 9.6a, we will attain:
where Z is the length of action from equation 9.2 and Pb is the base pitch from equation 9.4b.
The contact ratio mp can also be expressed as a function of pressure angle φ, number of pinion
teeth Np, and the gear ratio mG, as
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Gear Types
Spur Gears
Herringbone Gears
Worm Gears
Bevel Gears
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Spur Gears
• Teeth ║ to the axis of shaft 𝑶𝒖𝒕𝒑𝒖𝒕 𝑷𝒐𝒘𝒆𝒓
𝑬𝒇𝒇𝒆𝒄𝒊𝒆𝒏𝒄𝒚 =
𝑰𝒏𝒑𝒖𝒕 𝑷𝒐𝒘𝒆𝒓
• Based on rolling Cylinders
• Simplest
• Low Cost
• High efficiency (98-99%)
• Noisy & Prone to vibrations
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Helical Gears
• Teeth are at a helix angle ψ with respect to the axis of the gear
• Less noisy than spur gears
• More stronger due to the slightly thicker tooth
• Types of Helical Gearsets
1. Parallel helical gears (line contact, can handle heavy loads at high speed)
2. Crossed axis helical gears (point contact, suitable for light load applications)
• Efficiency of 96-98% for parallel and 50-90% for crossed
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Herringbone Gears
• Formed by joining two helical gears of identical pitch and diameter.
• They consist of two gear teeth sets on the same gear, one on right hand and other on
left hand side.
• From the top, each helical groove of herringbone gear looks like the letter V, and
many together form a herringbone (resembling the bones of fish).
• Eliminate the thrust force
• 95% efficient
• Give smooth operation at higher speeds
• Very expensive
• Generally, used in high-power applications
such as ship drives
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Rack and Pinion
• If base circle diameter of a gear increased to ∞ , it results in a linear gear called the Rack.
• Rack & pinion drive consist of a circular gear (i.e. the pinion) and the linear gear (i.e. the rack).
• Convert rotary to linear motion and vice versa.
• Rack has trapezoidal teeth, but yet are true involutes
• Application:
• Rack-and-pinion steering in automobiles,
• Generate horizontal & vertical movements, etc.
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Worm Gears
• Used to transmit motion between non intersecting, non parallel shafts.
• Comprised of worm & worm wheel
• Worm has only 1 teeth, wrapped continuously around its circumference
• Worm is meshed to worm gear (i.e. worm wheel), whose axis is ┴ to that of worm.
• High gear ratio & 40-85% efficient
• Carry heavy loads
• Can only be driven from worm
• Impossible to back drive
• Can be used in load bearing applications without brakes
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Bevel Gears
• Crossed helical gears are used for right-angle drives.
• Bevel gears are used for any angle between the shafts (including 90°).
• Bevel gears are based on rolling cones.
• Apices of the cones must intersect, otherwise there will be a velocity mismatch.
• By using pitch diameters, the velocity ratio of the bevel gears is given by equation 9.1a
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Comparison !!
Straight Bevel Gears Spiral Bevel Gears Hypoid Gears
Hypoid gears are used instead
Teeth are parallel to the axis of the Teeth are angled to the axis of the of bevel gears if the axes
gear gear between the gears are: non-
parallel & non-intersecting
Cone axes and apices must intersect Cone axes and apices must
--
in both cases. intersect in both cases.
Based on rolling hyperboloids
Based on rolling cones Based on rolling cones
of revolution
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Vee Belts
• Vee belts are made of elastomers (synthetic rubber) reinforced with synthetic or metallic cords for
strength
• Pulleys are used to grip the belt and tension of belt jams the belt into vee groove of pulley.
• Transmission efficiency - 95 to 98% - freshly installed
• Efficiency decreases to 93% as belt wears and slippage increases
• Because of Slip- Velocity ratio is neither exact nor constant
Synchronous (Timing) Belts
• Synchronous belt solves phasing problem by preventing slip while retaining some of advantages of
Vee belts
• More economical than gears or chains
• Made of rubber like material, reinforced with steel or synthetic cords for higher strength
• Molded-in teeth that fit in grooves of pulleys
• Fairly high torque and power transmission levels
• More expensive than conventional vee belts
• Noisier, run cooler and last longer
• Transmission efficiency - 98% and stays at that level with use
• Application - automotive engine camshafts
Chain Drives
• Chain drives are suitable for applications, which are subjected to large torque requirements or high
temperature levels, for which timing belts are not suitable.
• When input and output shafts are farther apart - chain drive - most economical choice
• Conveyor systems often use chain drives to carry work along assembly line
• Steel chains (but not all) are suitable for aggressive chemical or temperature environments
• Used in various applications ranging from common roller chain (bicycle or motorcycle) to more
expensive chain drives in expensive automobile engines.
• Sprocket teeth are not involutes
• Chain drives do not exactly obey fundamental law of gearing
• Links of chain form set of chords when wrapped around circumference of sprocket
Simple Gear Train
• Definition: Gear train in each shaft carries only one gear on it.
• The velocity ratio mv (also called train ratio) of simple gear train is given by equation:
• The train ratio of a simple gear train is always the ratio of the first gear over the last.
• Numerical effects of remaining (intermediate) gears are cancelled out.
• Only the sign of the overall ratio is affected by the intermediate gears which are called
idlers.
• In simple gear train, Output gear direction will be:
• Same as input - if odd number of external gears are present in train
• Opposite to input - if even number of external gears are present
• Thus adding a single, external idler gear (of any diameter) changes the direction of
the output gear without affecting its velocity.
• Gear ratio is limited ≤ 10:1 because of size and cost constraints.
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Simple Gear Train
• Simple gear train of many gears become more expensive than chain or belt drive, when it is
used to connect two shafts that are far apart from each other.
• It contain series arrangement of gears 32
Compound Gear Trains
• Definition: Gear Train in which at least one shaft carries more
than 1 gear.
• Gears fixed on same shaft have same angular velocity.
• Provides Gear ratio > 10:1.
• It contain Parallel or series-parallel arrangement of gears.
• Train ratio of Compound gear train is given by equation:
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Compound Gear Trains
• In compound gear train, intermediate ratios do not cancel each other.
• Overall train ratio is the product of the ratios of parallel gearsets.
• The ± sign in equation 9.8b depends on:
• number of meshes
• Type of meshes (external or internal).
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Example 9-2: Design a compound train for an exact train ratio of 180:1. Find a
combination of gears that will give that ratio.
Solution:
1. Determining how many stages, or gearsets, are necessary.
180 = 13.416 > 10: 1 2 − 𝑠𝑡𝑎𝑔𝑒𝑠, 𝑏𝑢𝑡 𝑑𝑜 𝑛𝑜𝑡 𝑙𝑖𝑒 𝑤𝑖𝑡ℎ𝑖𝑛 10: 1 𝑙𝑖𝑚𝑖𝑡𝑎𝑡𝑖𝑜𝑛
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180 = 5.646 < 10: 1 3 − 𝑠𝑡𝑎𝑔𝑒𝑠 𝑤𝑖𝑙𝑙 𝑏𝑒 𝑛𝑒𝑒𝑑𝑒𝑑
OK to proceed further as 5.64 is within the range of 10:1
2. Estimating no. of Gear teeth of Pinion (smaller gear):
• The no. of gear teeth must be an integer.
• Table 9-6 shows all the possible gear sets in which 79.05 is the closest value to
an integer.
• Pinion teeth should be = 14
• Thus 79:14 is closest to the desired ratio.
79 3
Check: Applying this ratio to all 3-stages, we have = 179.68: 1
14
(180−179.68)
Error calculation: ×100 = 0.2%
180
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Acceptable solution but not for timing applications.
Method to find the Exact Ratio:
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Types of Compound Gear Trains
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Types of Compound Gear Trains
• Non-reverted Compound Train: Gear trains in which input and output shafts are not coincident
(inline).
• Reverted Compound Train: Gear trains in which input and output shafts are coincident (inline).
• E.g. Used in automobile transmissions.
• The design of a reverted compound train is more complicated because of the additional constraint
expressed in terms of their:
• pitch radii,
• pitch diameters,
• or numbers of teeth (provided that all gears have the same diametral pitch)
For reverted gear trains:
If diametral pitch, pd is the same for all gears, then equation 9.4c can be substituted in equation
9.9b, to attain (expressing gear radii in terms of gear teeth)
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Example 9-3: Design a Reverted compound train for an exact train ratio of 18:1.
Solution:
1. Determining stages, or gearset ratios, are necessary.
18 = 4.24 < 10: 1
2 − 𝑠𝑡𝑎𝑔𝑒𝑠 𝑎𝑟𝑒 𝑠𝑢𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 & 𝑤𝑖𝑡ℎ𝑖𝑛 10: 1 𝑙𝑖𝑚𝑖𝑡𝑎𝑡𝑖𝑜𝑛
2. Estimating no. of Gear teeth of Pinion (smaller gear):
• Table 9-3 shows all the possible gear sets in which we are not getting exact
solution (integer).
Method to find the Exact Ratio:
• Given train ratio = 18:1 (integer)
• Find the 2 integer factors of 18 i.e. 18= 9*2 & 6*3 (factors are within the
range of 10:1)
• Minimum pinion teeth = Unknown
• We know that
• Using equation 9.9c and setting it equal to an arbitrary constant K:
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We know that
𝑵𝟐 𝑵𝟒
× = 𝟏𝟖 (𝟔 × 𝟑)
𝑵𝟑 𝑵𝟓
𝑵𝟐 𝑵𝟒
=𝟔 =𝟑
𝑵𝟑 𝑵𝟓
• By using assumption of K =112, eq. (f), & (g) will give value of N3
& N5 . Then value of K, N3 & N5 will be substituted in eq. a to
attain:
N2=96, N3=16,
N4=84, N5=28
• Check:
• Putting values:
96 84
𝑚𝑉 = − × − = 6 × 3 = 18
16 28 42
Conventional vs Epicyclic or Planetary Gear Trains
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Conventional vs Epicyclic or Planetary Gear Trains
• Conventional gear trains are 1-DOF devices (Figure 9-33a) in which
link 1 is immobilized grounded link.
• Epicyclic trains are 2-DOF devices (Fig. b) in which joint O2 is only
grounded while the arm rotates freely, that connects the two gears.
• Epicyclic gear train consist of a sun gear and a planet gear orbiting
around the sun, held in orbit by the arm.
• Generally, Epicyclic train require two inputs to drive the arm and the
sun gear with some velocity.
• When one of these inputs become zero, (i.e., by applying brake to either
arm or the sun gear) epicyclic train converts to conventional gear train
(Figure 9-33a).
• ∴ Thus, conventional gear train is a special case of more complex
epicyclic train, in which its arm is held stationary.
• In an epicyclic train, the only gear left to take an output is the planet
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gear.
Epicyclic Trains with Ring Gear
• Epicyclic or planetary gear train consist of a sun gear (@input) a
planet gear (@ output) orbiting around the sun, held in orbit by the arm
(@input).
• Applications like automotive differential uses one input (the
driveshaft) to obtain two outputs (the two driving wheels).
• Applications like automotive automatic transmissions, aircraft engine
to propeller reductions, and in-hub bicycle transmissions, uses two
inputs to obtain one controlled output.
• It becomes difficult to get output from orbiting planet gear as its pivot is
moving.
• This problem is solved by adding Ring gear (Figure 9-34), which meshes
with the planet, having pivot at O2, and now used as output member.
• Most epicyclic trains are arranged with ring gears to bring the planetary
motion back to a grounded pivot.
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Levai’s Catalogue of Epicyclic Gear Trains
• Epicyclic trains come in many varieties.
• Levai cataloged 12 possible types of basic epicyclic trains as shown in Figure 9-35.
• Above basic trains can be connected together to create a larger number of trains having more DOF.
• This is done in automatic transmissions of automobiles, as discussed in a later section. 46
Different Epicyclic Configurations
Gear plots are about axis of rotation or axis of symmetry
common shaft
External bearing
Gear Ring
(internal gear)
teeth
Internal
Gear
Axis of
Due to axis of symmetry symmetry
Sun
(external gear)
External Internal
Gear Gear
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Compound Epicycloidal Gear Train
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2
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Some Examples!!!
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Epicyclic or Planetary Gear Trains
• In conventional gear train, it is relatively easy to visualize the power flow and to observe the
motion direction of member gears.
• In planetary train it is very difficult to determine the motion behavior by observation.
• In planetary train, gears rotate w.r.t to arm and the arm itself has motion. So we have a velocity
difference problem given by following velocity difference equation:
• Equations 9.12 and 9.5a will be solved simultaneously for the velocities in an epicyclic train,
provided that the tooth numbers and two input conditions are known.
One approach used for velocity analysis of gears in epicyclic train is to create a table which
represents equation 9.12 for each gear.
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Example 9-5: Find the absolute output angular velocity of Ring gear of epicyclic gear
train shown in Figure 9-34.
Given:
Sun Gear N2 = 40-tooth external gear
Planet Gear N3 = 20-tooth external gear
Ring Gear N4 = 80-tooth internal gear
Input to arm 200 rpm clockwise
Input to sun 100 rpm clockwise
Solution: • Equations 9.12 and 9.5a will be used to solve the problem.
Sign convention:
• A solution table will be drawn, having
Clockwise is negative (-)
• a column for each term of Equations 9.12, and
Anti-clockwise is positive(+)
• a row for each gear in the train.
• Table will be arranged so that meshing gears (2&3, 3&4) will occupy adjacent rows.
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Given:
• Gear ratios are shown overlapping the gear rows, to which they apply.
• Gear ratio column is placed next to the relative velocity differences column ω gear/arm because the gear
ratios will be only applied to the relative velocity difference column.
• The gear ratios cannot be directly applied to the absolute velocities in the ω gear column.
• Take special care of sign of input velocities and of the gear ratios otherwise answer will be wrong.
Take anticlockwise rpm as positive & vice versa 53
Example 9-5 Continued!!!
• In this example, the arm velocity was given as input.
• To find arm velocity as output, then it must be entered in the table as an unknown, x, and the
equations should be solved for that unknown.
𝝎𝒐𝒖𝒕 −𝟐𝟓𝟎
𝑶𝒗𝒆𝒓𝒂𝒍𝒍 𝒕𝒓𝒂𝒊𝒏 𝒗𝒂𝒍𝒖𝒆, 𝒎𝑽 = = = +𝟏. 𝟐𝟓
𝒂𝒓𝒎
𝒓𝒊𝒏𝒈 𝒈𝒆𝒂𝒓
𝝎𝒊𝒏 −𝟐𝟎𝟎
𝝎𝒐𝒖𝒕 −𝟐𝟓𝟎
𝑶𝒗𝒆𝒓𝒂𝒍𝒍 𝒕𝒓𝒂𝒊𝒏 𝒗𝒂𝒍𝒖𝒆, 𝒎𝑽 = = = +𝟐. 𝟓
𝒔𝒖𝒏 𝒈𝒆𝒂𝒓
𝒓𝒊𝒏𝒈 𝒈𝒆𝒂𝒓
𝝎𝒊𝒏 −𝟏𝟎𝟎
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Advantages of Epicyclic over Conventional Gear Trains
• Epicyclic trains offer several advantages, like:
• higher train ratios in smaller packages,
• reversion by default,
• simultaneous, concentric, bidirectional outputs available from a single unidirectional input.
• These features make planetary trains popular for automatic transmissions of automobiles
and trucks, etc.
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5 5
2 3 4
• Problems = 9- 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23,
24, 26a, 27, 52, 53, 54, 55, 56, 58, 69, 70, 71,
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