Machine design ME322

Course-2-0-2

Week-1 Lecture-1 Introduction

Course Instructor: Dr. Poonam Kumari

Associate Professor
Department of Mechanical Engineering
IIT Guwahati, Guwahati-781039
Contents

2.1 Introduction
2.2 Nomenclature of involute spur gears
2.3 Meshing of gears
2.4 Interference in gears
2.5 Methods of eliminating interference
2.6 Minimum number of teeth to avoid interference
2.7 Length of line of action
2.8 Contact ratio

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 1.12a Involute Gear Tooth Profile
• Involute is the path generated by the end of a thread as it unwinds from a reel. In order to understand
what is involute, imagine a reel with thread wound in the clockwise direction as in Fig.1.23. Tie a knot
at the end of the thread.
In the initial position, the thread is at B0 with knot on the reel at C0. Keeping the reel stationary, pull
the thread and unwind it to position B1. The knot now moves from C0 to C1. If the thread is
unwound to position B2 the knot moves to C2 position. In repeated unwinding, the taut thread
occupies position B3, B4 while the knot moves to C3, C4 positions. Connect these points C0 to C4 by a
smooth curve, the profile obtained is nothing but an involute, the illustration of which is given below.

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 This forms the left side part of the tooth profile. If similar
process is repeated with thread wound on the reel in
anticlockwise direction in the same position, it forms the
right side part of the same tooth.
The completely formed involute tooth is shown in Fig.1.25

https://www.youtube.com/watch?v=-V8mfHcnf08

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Advantages of Involute Gears

• 1. Variation in centre distance does not affect the velocity ratio.

• 2. Pressure angle remains constant throughout the engagements which results in smooth running.
• 3. Straight teeth of basic rack for involute admit simple tools. Hence, manufacturing becomes
simple and cheap.

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1.12b Cycloidal Gear Tooth Profile

• Cycloid is the locus of a point on the circumference of a circle when it rolls on a straight line
without slipping. If the circle rolls on the outside of another circle or inside of another circle gives
rise to epicycloid and hypocycloid respectively. This is illustrated in Fig. 1.27. The profile of a
cycloidal tooth consists of two separate curves or double curvature. This tooth form also satisfies
the law of gearing or conjugate action similar to an involute gear.

https://www.youtube.com/watch?v=u5XqDmhlesg

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 Advantages of Cycloidal Gears

1. Cycloidal gears do not have interference.

2. Cycloidal tooth is generally stronger than an involute tooth owing to spreading flanks in contrast to
the radial.
3. flanks of an involute tooth.
4. Because of the spreading flanks, they have high strength and compact drives are achievable.
5. Cycloidal teeth have longer life since the contact is mostly rolling which results in low wear.

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 Disadvantages of Cycloidal Gears

1. For a pair of Cycloidal gears, there is only one theoretically correct center distance for which a
constant angular-velocity ratio is possible.
2. The hob of Cycloidal gear has curved teeth unlike involute rack teeth. Hence hob manufacture is
difficult and costly.
3. Cycloidal gear will cost more.

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1.12c Novikov, Wildhaber or Circular Arc Tooth Profile

The Novikov gears are having circular tooth surfaces in the transverse section Fig. 1.31. Normally
pinion has a convex tooth profile and the gear tooth has a concave tooth profile. They can also have
concave profile for pinion and convex profile for the gear or convex profiles for both.
The teeth of Novikov gears have point contact in mesh. Hence to increase the contact ratio the teeth
are made helical and appearance of Novikov gear is shown in Fig.1.32.
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• The height of a Novikov gear tooth is about half of the corresponding an involute tooth of the
same module. Hence these teeth can with stand high load with weight of the gears approximately
half the size of involute gears. Since these gears are having pure rolling action at the contact, their
efficiency is as high as 99.5%.
• Novikov gear also satisfies the law of gearing since the common normal to the gears at the point
of contact will always be passing through a fixed point, viz., pitch point as illustrated in Fig. 1.31
and in more detail in Fig. 1.33. Hence these profiles are conjugate to each other and pressure angle
remains constant.

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 Advantages of Novikov Gears
1. A convex surface is always in contact with another concave surface.
2. The beam strength is much higher for the pinion than for the gear when the gear is much larger
than the pinion.
3. The contacting teeth have rolling action and hence wear is less.
4. If the convex profile is on the pinion teeth, and within the practical limits, the radii are close to the
same value to provide the maximum possible wear strength.

Disadvantages of Novikov Gears

1. The circular-arc profiles are not conjugate and consequently, in a plane each tooth can make
contact at only one point in each revolution.
2. The circular-arc gears are very sensitive to variations in center distances and are hence best suited
for slow-speed operation.
3. For the circular-arc gears in a plane, the contact ratio is zero. Hence, the circular-arc teeth cannot
be used on spur gears but must be used on helical gears, where the contact ratio for the gear can be
made greater than 1.0 by providing overlap ratio.

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Applications of Novikov or Circular Arc Gears

24/04/2024 Fig 1.34 Slow speed Gear boxes 12

 2.1 INTRODUCTION
• The function of a gear is to work smoothly while transmitting motion or torque. For this the
angular velocity ratio at all times should remain constant. This aspect is explained here using
various gear terminology that are peculiar to gears. Understanding of the definition of these
terminologies helps to grasp the functioning of gears and the design of gears.

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 2.2. NOMENCLATURE OF INVOLUTE SPUR GEARS
Refer to the Figs.2.1 which show a portion of a pair of involute gears in mesh.
• Pitch circle: It is a theoretical circle upon which all calculations are usually based.
• Pitch circle: It is the diameter of the pitch circle.
• Pinion is the smaller of two mating gears. The larger is often called the gear.
• Circular Pitch (p) is the distance measure on the pitch circle from a point on one tooth to a
corresponding point on an advancement tooth. Thus the circular pitch is equal to sum of the tooth
thickness and width of space.
• Module (m) is the ratio of the pitch diameter to the number of teeth. Module is the index of tooth
size.
• Diametral Pitch (P) is the ratio number of teeth on a gear to the pitch diameter. It is reciprocal of
module
• Addendum circle: A circle bounding the ends of the teeth, in a normal section of the gear.
• Dedendum circle or Root circle: The circle bounding the spaces between the teeth, in a normal
section of the gear.

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2.2. NOMENCLATURE OF INVOLUTE SPUR GEARS
• Addendum (a): The radial distance between the pitch circle and the addendum circle.
• Dedendum (b) : The radial distance between the pitch circle and the root circle.
• Clearance (c) : The difference between the Dedendum of one gear and the addendum of the
mating gear.
• 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.
• Top land: The top surface of a gear tooth.
• Bottom land: The bottom surface of the tooth space.
• Whole Depth: ht is the sum of addendum and dedendum.
• Blacklash is the amount by which the width of a tooth space exceeds the thickness of the
engaging tooth measured on the pitch circle.
N • P=diametral Pitch, teeth per inch
P
d
• N=number of teeth
d
m
N • d= pitch diameter
d • m = module
p m
N
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pP   • p=circular pitch 15
•

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 Conjugate Action

When the tooth profiles or cams are designed so as to produce a constant angular velocity ratio
during meshing, these are said to have conjugate action. Theoretically, at least, it is possible
arbitrarily to select any profiles for one tooth and then to find a profile for the meshing tooth that
will give conjugate action. Involute profile produce the conjugate action.
Tracing points

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 Fundamentals

Angular Velocity ratios

1 r1
 V  r11  r22
2 r2
Pressure Line, generating line and line of action
Pressure angle
rbi  ri cos  i=1,2
ri  pitch radious of gear i
rbi  radius of base circle of gear i
pressure angle range: 20o to 25o , previously it was 14.5o
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Lets us design a speed reducer with input speed 1800 rev/min and output speed 1200 rev/min

. 1 1800 3 r1
  
2 1200 2 r2
For this case, we can use diameter of gear and pinion keeping the ratio same. We can choose radius
of pitch circle of gear 6 inch and 4 inch pinion.

For a given pitch (P)., 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

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• Pitch point: The point of tangency of the pitch circles of a
pair of mating gears.

• Common tangent: The line tangent to the pitch circle at

the pitch point.

• Line of action: A line normal to a pair of mating tooth

profiles at their point of contact.

• Path of contact: The path traced by the contact point of a

pair of tooth profiles.

• Pressure angle φ: The angle between the common normal

at the point of tooth contact and the common tangent to
the pitch circles.

• Pressure angle is also the angle between the line of action

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and the common tangent.
 N
P
d
d
m
N
d
p m
N
pP  

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The effect of diametral pitch on the size of the gear tooth is shown in Fig. 2.3

Actual tooth size for various diametral pitches is shown in Fig.2.4.

The diametral pitches are standardized and these values are given
in Table 2.1.

Table 2.1 Standard diametral pitches

1 1.25 1.5 1.75 2 2.5 3
4 5 6 8 10 12 14
16 18 20 24 32 48 64
72 80 96 120

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 In metric system, module is used instead of diametral pitch. It is nothing but the inverse of diametral
pitch. The standard modules for which cutters are readily available in the market are given in Table
2.2

0.3 0.4 0.6 0.7 0.8 1.0

1.25 1.5 2.0 2.25 2.5 3
3.5 4 5 5.5 6 6.5
7 8 10 11 12 13
14 15 18 20 22 24
26 28 33 36 39 42
45 50 Further increase is in terms of 5 mm

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Gear meshing

• Having known various terminologies during meshing

of gears, how the contact points traverses is illustrated by
flash in Fig. 2.8.
• It can be seen clearly during operation the
contact point demarked by red point is
established on the left hand side of the axis
joining the centre of the gears and moves to
the right and vanishes.
• New contact is established again at the left
side.
• It moves along the straight line known as line
of action which is tangent to both the base circles. The angle made by it with the common
tangent to the pitch circles at the pitch point is known as the pressure angle. It can be noted that the
line of action passes through the pitch point which is the point of intersection of the line connecting
the centres of the gears with the common tangent.
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Contact ratio

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• If the portion of the gear exists below the base circle, then it results in interference and leads to
undercutting of the tooth. In Fig. 2.9 the shaded portion of the teeth are below the base circles.
They are going to cause interference. In Fig.2.10 portion of the pinion tooth below the gear tooth
surface is seen.
2.4 Gear tooth Interference

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• Fillet Radius: The small radius that connects the profile of a tooth to the root circle.
• Crowning: Grinding of tooth edges to prevent edge loading is known as crowning. This is shown
in Fig. 2.5.

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In practice this cannot happen unless the part of the gear tooth is relieved of material causing this
interference. This is achieved by the harder pinion tooth removing away the portion of the gear tooth
to avoid interference. Note that the tooth portion below the base circle is not having involute profile.
Such a situation will arise when a gear with a certain number of teeth mates with pinion having
number of teeth below a critical value.

2.5 Methods of elimination of Gear tooth Interference

In certain spur designs if interference exists, it can be overcome by:

• Removing the cross hatched tooth tips i.e., using stub teeth
• Increasing the number of teeth on the mating pinion.
• Increasing the pressure angle
• Tooth profile modification or profile shifting
• Increasing the centre distance as illustrated in fig.2.11.
For a given gear, the interference can also the eliminated by increasing the centre distance.
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