MEC 410

Design of Machine Elements

Spring 2017
Chapter 8
Jay Mendelson
Lecturer
Mechanical Engineering Department
Jay.Mendelson@stonybrook.edu
Normal office hours 1PM 3PM
Monday and Wednesday
171 Light Engineering
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 MEC 410: Chapter 8: Kinematics of Gears

Reading: Chapter 8 in Machine Elements in

Mechanical Design 5th Edition
Homework Problems from Textbook:
Gear Geometry problem 3, but with 2 gears where
Np = 15 and Ng = 45. Also, calculate the contact ratio mf
Helical Gear problem 42
Bevel Gear Geometry problem 51
Worm Gear Geometry problem 54
Analysis of Complex Gear Trains problem 59
Kinematic Design of Gear Trains problem 69

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 Gear Drives
Gears are toothed, cylindrical wheels used for transmitting
motion and power from one rotating shaft to another
Usually used to decrease speed and increase torque from
the input to output shaft.
Highly efficient with output power approximately equal to
input power

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 Gear Drives are Fixed Transmissions
All components are rigidly mounted to fixed
shafts, usually inside a sealed housing.
Alignment is critical.
Speed reduction ratio, np/ng = Ng/Np
Torque increase ratio = 1/speed reduction ratio
Pinion attaches to input shaft, has Np
number of teeth and rotates at speed np

Gear attaches to output shaft, has Ng

number of teeth and rotates at slower
speed ng

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 Applications for Gear Drives
Very large increases in torque from very high speed, low torque
power sources, accomplished in a tight package space. Best known
application is the transmission for gas powered autos
Change in direction of rotation speed. Used in differential for rear-
wheel drive, gas powered cars From drive shaft connected To rear wheel
to Transmission (2x)

Differential
Image source: www.wisegeek.com Transmission

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https://d2t1xqejof9utc.cloudfront.net/screenshots/pics/34
798f21a8b3f44d2aa2b9b7d1722956/medium.gif
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 Types
of Gears

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 How a Spur Gear Drive Works
As the input and
output shafts
rotate, the teeth
engage and the
input teeth push
on the output
teeth in a
direction
tangential to the
Speed reduction
axis of rotation.
ratio = Ng/Np =
11/18 = .61

https://en.wikipedia.or
g/wiki/Gear

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 Advantages of a Gear Drive

Gear drives are more compact than chain or belt drives

because center distances are minimum.
Gears can operate at higher speeds than either belts or
chains.
Gears have a greater range of speed ratios than chains.
Gears can better transfer high power at high speed than
can either belts or chains.
Metal gears do not deteriorate with age, heat or oil and
grease and they do not develop static electric charges.

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 Gear Geometry: The Involute Curve

An Involute is one of a class of

geometric curves called
conjugate curves
When two such gear teeth in
mesh and rotating, there is
constant angular velocity ratio
between them; resulting action
Imagine the very smooth.
tangent line Involute curve
as a piece of on side of gear
string tied tooth
here

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 Gear Tooth Geometry
Pitch Circle : theoretical
circle upon which the
involute curves are built.
Pitch Diameter, D : The
diameter of the pitch
circle.
Circular Pitch, p : The
circumferential distance
on the pitch circle, from a
point on one tooth to the
corresponding point on
the adjacent tooth.
Pitch of the two gears in
mesh must be identical
Addendum, a: Radial distance between top land and pitch circle.
Dedendum, b: Radial distance from bottom land to pitch circle.
Face: Thickness of the tooth
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 Spur Gear Geometry Equations

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 Pressure Angle
Surface of
gear tooth Tangent to
pitch circles

Line drawn
to surface
of gear
tooth

Pressure angle: the angle between the tangent to the pitch

circles and the line drawn perpendicular to the surface of the
gear tooth

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 Changing the Pressure Angle Changes
the Shape of the Gear Tooth

Most common pressure angle Big air gap between teeth

Very good transmission of forces Risk of slippage
Risks interference if dimensions Not much chance for interference
are off Tooth very strong due to large
Tooth can break due to undercut at sculpted base and small top
the base
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 Providing Gear Backlash Reduces the Gear
Stresses

Backlash: The amount by which the width of a tooth space exceeds

the thickness of the engaging tooth measured on the pitch circles.
(space width of one gear) - (tooth thickness of other gear)
You increase backlash by:
Adjust the center distance larger than theoretical value (preferred)
Machine custom gears by feeding the cutter deeper into the gear
blank
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 Minimum Recommended Backlash

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 Contact Ratio Indicates Minimum Number of
Teeth in Contact at any Time

mf must be >1.2,
with typical spur
gears around 1.5

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 Gear Geometry Problem Number 2 with
Two Gears, Instead of One Gear

g and Np = 17
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 Solution to Gear Geometry Problem Number 2:
Use Table 8-1 formulae
Problem number: 8-2 with two gears
Input data:
Gear Number of teeth: N g = 34
Pinion Number of teeth: N p = 16
Diametral pitch: P d = 24
Pressure angle: f = 20 degrees

Computed results: Formula

(a) Gear Pitch diameter: D g = 1.4167 in Dg = Ng/Pd
Pinion Pitch diameter: D p = 0.6667 in Dp = Ng/Pd

(b) Circular pitch: p = 0.1309 in p = /Pd

c) Equivalent module: m = 1.0583 mm m = 25.4/Pd

d) Nearest Standard module 1.0000 mm Use Table 8-4

e) Addendum: a = 0.0417 in a = 1/Pd

(f) Dedendum: b = 0.0521 in (Coarse) 0.0520 in (Fine) b = 1.25/Pd

(g) Clearance: c = 0.0104 in (Coarse) 0.0103 in (Fine) b = 0.25/Pd

(h) Whole depth: h t = 0.0938 in (Coarse) 0.0937 in (Fine) ht = a + b

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 Solution to Gear Geometry Problem Number 2:
(contd)
(i) Working depth: h k = 0.0833 in hk = 2 x a

(j) Tooth thickness: t = 0.0654 in t = p/2

(k) Gear Outside Diameter: D og = 1.5000 in Dog = (Ng + 2)/Pd

(l) Pinion Outside Diameter: D op = 0.7500 in Dop = (Np + 2)/Pd

(m) Gear Outside Radius: R og = 0.7500 in Rog = Dog/2

(n) Gear Outside Radius: R op = 0.3750 in Rop = Dop/2

(o) Radius of base circle for Gear: R bG = 0.6656 in RbG = (Dg/2) x cos ()

(p) Radius of base circle for pinion: R bP = 0.3132 in RbP = (Dp/2) x cos ()

(q) Center Distance: C = 1.0417 in C = (Np + Ng)/(2 x Pd)

(r) Contact Ratio mf = 1.59

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Note: mf is > 1.2
 Potential Interference Between Mating Teeth

Optimal Center Distance

for driving teeth has a
bad side effect: the tip of
the pinion bottoms out
on the root of the gear

Greatest with small pinion driving a rack or large gear

Best to use guidelines per table 8-7 to prevent interference

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 How a Helical Gear Drive Works

Teeth are inclined at

the helix angle
Parallel-axis helical
gears are used
extensively in
vehicle
transmissions due
to quiet running
Right (left) handed
teeth appear to
learn right (left)
when the gear is
laid down flat
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Pros and Cons of a Helical Gear Drive vs. Spur Gear Drive

Pros:
Runs very quietly due to a tooth assuming load gradually as the
gears rotate, rather than all at once
Greater strength for the same size gear.
Cons:
Greater cost than spur gears
Introduces axial component of force on the mating shaft, and
requires thrust bearings to support the force

https://grabcad.com/library/helical-gear-with-involute-teeth-profile-1
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 Primary Helical Gear Forces

Tangential force Wt
acts tangential to the
pitch surface and to
the shaft axis
Radial force Wr acts
towards the center of
the mating gears,
tending to push them
away from each other
Axial force Wx acts
parallel to the shaft,
also known as the
thrust force

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 Primary Helical Gear Angles and Planes

Plane containing the

tangential force Wt and
axial force Wx is the
tangential plane
Plane containing the
tangential force Wt and
radial force Wr is the
transverse plane
Plane containing the
true normal force Wn
and radial force Wr is
the normal plane
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 Helical Gear Circular Pitch

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 Helical Gear Diametral Pitch

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 Helical Gear Metric Module

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 Helical Gear Metric Module

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 Helical Gear Geometry Problem Number 41

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 Solution to Problem Number 41
Input data:
Number of teeth: N = 45
Transverse Diametral pitch: P d = 8
Transverse Pressure angle t 14.5 degrees
Helix angle: y = 30 degrees
Degrees per Radian = 57.296 degrees
Face width: w = 2 inches

Computed features for helical gears: Formula

(a) Circular pitch: p = 0.3927 in p = /Pd

(b) Normal circular pitch: p n = 0.3401 in pn = p cos(y)

c) Normal diametral pitch: P nd = 9.238 Pnd = Pd / cos(y)

(d) Axial pitch: Px = 0.6802 in Px = p / tan(y)

e) Pitch Diameter, D = 5.6250 in D = N / Pd

(f) Normal Pressure angle n = 12.624 degrees tan-1 ( tan (t) cos(y))

(g) Number of axial pitches = 2.940 No. = w/ Px

Minimum No. of axial pitches = 2.0000

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 How a Straight Bevel Gear Drive Works

Teeth are straight, but the

top land of the gear is angled
at the pitch cone angle
The main axes of the gears
are usually perpendicular to
Image source: www.linngear.com
each other
In addition to speed
reduction and torque
increase, you also change
the axis of rotation by 90
Used in automotive
differentials
http://www.zakgear.com/Art1.html

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 Other Types of Bevel Gears
Spiral Gear: Teeth are angled with
respect to axis at a spiral angle, just
like helical gear. Low vibration, low
noise at high speeds. Thicker teeth
in direction of loading allows the
Image source: www.dir.indiamart.com gear to carry heavier loads than a
straight bevel gear.
Hypoid Gear: Teeth are angled and
spiral, but the main axes do not
intersect. Used for quiet action & to
save space
Image source: www.greenfries.info

Zero Spiral Gear: Teeth are curved, but

with zero spiral angle. Main axes
intersect. Used for quieter action, but
also as one for one sub for bevel gears.
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 Dimensions for Straight Bevel Gears
Pinion

Image source: www.allexpress.com Pitch Cone

Angle, Pinion

Gear Pitch Cone

Angle, Gear

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 Table 8-8 Has the Kinematic Formulae for
Straight Bevel Gears

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 Table 8-8 Has the Kinematic Formulae for
Straight Bevel Gears

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 Google Image Drawings Showing Dimensions

36 Image source: www.mymachineinfo.com

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 Google Image Drawings Showing Dimensions

Image source: www.daerospace.com

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 Google Image Drawings Showing Dimensions

38 Image source: www.chegg.com

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 Dimensions You See in a Gear Catalog

(Pd = 6)

(Pd = 8)

(Pd = 10)

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Image source: www.matinproucts.com
 Bevel Gear Geometry Problem Number 45

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Solution to Bevel Gear Geometry Problem Number 45
PROBLEM: 45
GIVEN DATA Variable
No of teeth in pinion = 15 NP
No of teeth in gear = 45 NG
Diametral pitch = 6 Pd
Pressure angle = 20 degrees (usually fixed at 20)

COMPUTED VALUES Formula

Gear ratio 3.000 mp = NG/NP
Pitch diameter: Pinion 2.500 in d= Np /Pd
Pitch diameter: Gear 7.500 in D = Ng / Pd
Pitch cone angle: Pinion 18.435 degrees = tan-1 (NP / NG)
Pitch cone angle: Gear 71.565 degrees = tan-1 (NP / NG)
Outer cone distance 3.953 in A0 = 0.5D / sin ()
FACE WIDTH F
Nominal face width 1.186 in Fnom = 0.30 A0
Maximum face width (a) 1.318 in Fmax = A0/3
Maximum face width (b) 1.667 in Fmax = 10/Pd
Max face width = smallest of (a) or (b)
INPUT Face width 1.000 in
41 COMPUTED VALUES
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Maximum face width (a) 1.318 in Fmax = A0/3
Maximum face width (b) 1.667 in
Fmax = 10/Pd
Solution to Bevel Gear Geometry Problem Number 45
Max face width = smallest of (a) or (b)
INPUT Face width 1.000 in
COMPUTED VALUES
Mean cone distance 3.453 in Am = A0 - 0.5F
Ratio A m /A o 0.874
Mean circular pitch 0.457 in pm = (/Pd) x (Am/Ao)
mean working depth 0.291 in h = (2.00/Pd) x (Am/Ao)
Clearance 0.036 in c = 0.125h
Mean whole depth 0.328 in hm = h + c
mean addendum factor 0.242 c1 = 0.210 + 0.290/(mg) 2
Gear mean addendum 0.071 in ag = c 1h
Pinion mean addendum 0.221 in ap = h - ag
Gear mean dedendum 0.257 in bg = hm-ag
Pinion mean dedendum 0.107 in bp = h - ag
Gear dedendum angle 4.257 degrees G = tan-1 (bp/Amg)
Pinion dedendum angle 1.774 degrees p = tan-1 (bp/Amg)
Gear outer addendum 0.086 in a0G = ag + 0.5F tan(p)
Pinion outer addendum 0.258 in a0P = ap + 0.5F tan(G)
Gear outside diameter 7.554 in D0 = D + 2aoG cos()
Pinion outside diameter 2.989 in d0 = d + 2aoP cos()
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 How a Worm Gear Drive Works
Used to transmit motion and
Worm
power between non-
intersecting shafts 90 apart
The worm is connected to
Gear
input power, usually a motor. It
drives the gear, typically with >
10X or more increase in torque
The worm has teeth very
similar in shape to a screw
thread. The Helix angle is very
large.
Used by your professor in a
Image source: www.framo-morat.com circular paper chart recorder
when the galaxy was young
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 Chart Recorder Using Worm Gear to Drive Pens
Plotting Temperature & Humidity Circa 1994

2 Worm Gear
Drives move
these pen
mechanisms back
and forth across
the paper, as
temperature and
Paper humidity change
Rotates 360
in 1, 7 or 31
days

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2/1/2017 Image source: www.omega.com
 Pros and Cons of a Worm Gear Drive

Pros
Very large gear ratios (up to about 360:1) in a compact package,
because of the small number of teeth on the worm.
If the lead angle of the worm is small enough (< about 6 degree)
the worm set can be self-locking, i.e., it cannot be back-driven
from the worm gear so that it will hold a load.
Locking action is produced by friction between worm threads
and the worm gear teeth
Cons
Relatively low efficiency compared to other gear sets.
The sliding (not rolling) motion between the teeth generates
significant heat.
Heat in a gearbox, not stresses in the teeth, limits a worm sets
life.
For high power applications, the oil temperature in the gear box
should be kept below about 200 degree Fahrenheit for long
45 tooth life. 2/1/2017
 Worm Gear Motion

http://forums.autodesk.com/autodesk/attachments/a
utodesk/12/141661/1/Worm%20Gear.gif
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 Worm Gear Geometry Equations

Image source: www.functionbay.co.kr

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 Worm Gear Motion Equations

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Worm Gear Dimensions

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 Worm Gear Geometry Problem Number 52

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Solution to Worm Gear Geometry Problem Number 52
Wormgearing - Design Problem 52

Input Data:
No. of worm threads: NW = 1
Pitch diameter: D w= 1.250 in
Diametral pitch: Pd = 10
Normal pressure angle: fn = 14.5 degrees
Specify No. of gear teeth: NG = 40
Nominal gear face width: F eG = 0.625 in
Calculated Data: Formula
Axial pitch of worm: px = 0.314 in px = p
Lead of the worm: L= 0.314 in L = NW px
Circular pitch: p = 0.314 in p = /Pd
Lead angle: l= 4.574 deg l = tan-1 (L/ Dw
Addendum: a= 0.100 in a = 1/Pd
Dedendum: b= 0.116 in b = 1.157/Pd
Worm outside diameter: D oW = 1.450 in DoW = Dw + 2a
Worm root diameter: D RW = 1.019 in D RW = D w - 2b
Gear pitch diameter: DG = 4.00 in D G = N G/P d
center distance: C= 2.625 in C = (Dw + DG)/2
velocity ratio: VR = 40.00 VR = NG / NW

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 Velocity Ratio and Gear Trains
Velocity Ratio = in / out
Substituting for radii,
diameters or speed in
RPM gives other equations

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 Gear Trains Have a Rotation Direction
Change at Each Stage

www.technologystudent.com

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 Train Value
Use Train value (TV)
when more than two
gears are in mesh

TV = (VR1)VR2) = (NBND)/(NANC)
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TV = (70)(54)/(20)(18) = 10.5
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 Idler Gears
Idler Gear: Any gear that performs as both a driving and driven
gear
Idler gears are used to fill a void between two gears when it is
not possible to bring their two shafts closer enough together to
meet the center distance requirement
Idler gears do not affect the TV, as the number of teeth appear
in the numerator and denominator of the TV equation
Idler gears cause 2 rotation direction reversals that cancel out

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2/1/2017 Image source: www.imgarcade.com
 Internal Gear
Internal Gear: teeth are machined on the inside of a ring,
instead of on the outside of a gear blank
The gear rotates in the same direction as the pinion

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2/1/2017 Image source: www.cogmatic.com
 Internal Gears are Used in Tight Spaces Where
Rotation Direction Must Remain the Same

www.softdevspb.com

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 Rack and Pinion
Rack and Pinion Gear Set: The gear (i.e. rack) has infinite
radius, so that it is flat
Used in car steering mechanisms

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2/1/2017 Image source: www.cogmatic.com
 Rules for Creating a Gear Train

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 Rules for Creating a Gear Train

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 Three Methods of Designing a Gear Train

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 Complex Gear Geometry Problem Number 58

Pinion (4x) Gear (4x)

Idler Gear

Shaft (6x)

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 Solution to Complex Gear Geometry Problem Number 58

Complex Gear Train Problem 58

Input Data: 3450 RPM cw direction Output Data:

No. Teeth Stage VR Formula Stage VR Change in Direction?
Pinion A No. of teeth: NA = 18
Gear B No. of teeth: NB = 82 NB/NA -4.56 Yes
Pinion C No. of teeth: NC = 17
Gear D No. of teeth: ND = 64 ND/NC -3.76 Yes
Pinion E No. of teeth: NE = 20
Gear F No. of teeth: NF = 110 NF/NE -5.50 Yes
Pinion G No. of teeth: NG = 18
Idler H No. of teeth: NH = 18 NH/NG -1.00 Yes
Gear I No. of teeth: NI = 38 NI/NH -2.11 Yes
Total VR -199.13 Yes

Input RPM 3450 clockwise

Output RPM 17.32 counter-clockwise

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 Kinematic Design Gear Trains Problem 67

Devise a gear train using external gears on parallel

shafts.
Use 20 full-depth involute teeth and no more than 150
teeth in any gear (Rule 10)
Ensure that there is no gear tooth interference (i.e. use
table 8-7 to satisfy Rule 9
Make a rough sketch of the layout 9 (i.e. like those of
problems 58, 59, or 60)
Input speed = 1800 rpm
Output speed is in the range of 21.0 to 22.0 rpm

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 Step by Step Procedure to Solve Problem 67
1. Use the Residual Ratio method. Use spur gears, as they are
the simplest and lowest cost gears for parallel shaft.
2. Nominal train value (TV) = 1800/21.5 = 83.7
3. From Table 8-7, if we use at least 17 pinion teeth, we can go
up to 1309 teeth with no interference. This is no problem, as
we are limited to 150 teeth max on any one gear
4. VRMAX per gear/pinion pair = 150/17 = 8.83
5. Suppose we did two gear/pinion pairs. The VR = 8.832 = 77.85
6. Because 77.85 < 83.7, we will need to use three pinion/gear
pairs
7. Lets try having three equal TVs. Then TV = 83.701/3 = 4.37
8. Now we must make sure that the number of teeth in any
gear be an integer (Rule 2), so we cant use 4.37
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 Step by Step Procedure to Solve Problem 67
9. Lets try using TVs near 4.37, like 4 or 5. This way we can
pick the number of pinion teeth and know that the
mating gear will have an integer number of teeth
10. In order to keep TV for the system at 83.7, we want to
alternate the individual TVs. Lets start with 5, then 4,
and see what last TV we need to get to 83.7
11. To keep the gear train compact, lets make the pinion
gears have 17 teeth each, the minimum needed to
prevent interference
12. Then NA = 17 and NB = 17 x 5 = 85.
13. Then NC = 17 and ND = 17 x 4 = 68.
14. The TV for two pinion/gear pair is 4 x 5 = 20
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 Step by Step Procedure to Solve Problem 67
15. Which means that the TV for the third pair = 83.7/20 =
4.19
16. Then NE = 17 and NF = 17 x 4.19 = 71.23
17. Then we must round NF to nearest integer. NF = 71. So
the actual TV of the third stage = 71/17 = 4.18
18. Lets calculate the revised system TV and output rpm.
19. TV = 4 x 5 x 4.18 = 83.53
20. Output rpm = 1800/83.53 = 21.55, which is between 21
and 22

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 Solution to Problem 67

Complex Gear Train Homework Problem 67

Input Data: 1800 RPM Output Data:

No. Teeth Stage VR Formula Stage VR
Pinion A No. of teeth: NA = 17
Gear B No. of teeth: NB = 85 NB/NA -5.00
Pinion C No. of teeth: NC = 17
Gear D No. of teeth: ND = 68 ND/NC -4.00
Pinion E No. of teeth: NE = 17
Gear F No. of teeth: NF = 71 NE/NF -4.18
Total VR -83.53

Input RPM 1800

Output RPM 21.55
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