11.

Gear Design

11. Gears Objectives

• Understand basic principles of gearing.
• Understand gear trains and how to calculate ratios.
• Recognize different gearing systems and relative advantages and
disadvantages between them.
• Understand geometry of different gears and their dimensional properties.
properties.
„ Recognize different principles of gearing.
„ Recognize the unorthodox ways gears can be used in different motion
motion
systems.

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Introduction
„ Gears are the most common means used for power
transmission
„ They can be applied between two shafts which are
„ Parallel
„ Collinear
„ Perpendicular and intersecting
„ Perpendicular and nonintersecting
„ Inclined at any arbitrary angle
Introduction
„ Gears are made to high precision
„ Purchased from gear manufacturers rather than
made in house
„ However it is necessary to design for a specific
application so that proper selection can be
made
„ Used to be called toothed wheels dating back
to 2600 b.c.

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An 18th Century Application of Gears for

Powering Textile Machinery

http://www.efunda.com/DesignStandards/gears/gears_history.cfm
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1
 11.2 Types of Gears

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Gear Types Gear Parameters

„ Spur gears „ Number of teeth
„ Internal gears „ Form of teeth
„ Most common form „ Size of teeth
„ Face Width of teeth
„ Used for parallel shafts
„ Style and dimensions of gear blank
„ Suitable for low to medium speed application „ Design of the hub of the gear
„ Relatively high ratios can be achieved (< 7) „ Degree of precision required
„ Steel, brass, bronze, cast iron, and plastics „ Means of attaching the gear to the shaft
„ Can also be made from sheet metal „ Means of locating the gear axially on the shaft

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Spur gear Gear Types

nomenclature

„ Helical gears
„ Teeth are at an angle
„ Used for parallel shafts
„ Teeth engage gradually reducing shocks

Kalpakjian • Schmid
August 15, 2007 Manufacturing Engineering 11
and August 15, 2007 12
Technology, Prentice Hall

2
 Helical Gears Helical Gear

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Helical Gear Characteristics Herringbone Gears

„ Helix angle 7 to 23 degrees „ Two helical gears with opposing helical angles
„ More power side-
side-by-
by-side
„ Larger speeds „ Axial thrust gets cancelled
„ More smooth and quiet operation
„ Used in automobiles
„ Helix angle must be the same for both the mating
gears
„ Produces axial thrust which is a disadvantage

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Herringbone Gears Herringbone Gear

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 Herringbone Gear Machining Gear Types
„ Bevel gears
„ They have conical shape

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Bevel Gears (Miter gears) Bevel Gears

For one-to-one ratio

Used to change the
direction

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Bevel Gears Gear Types

„ Worm gears
„ For large speed reductions between two perpendicular
and non-
non-intersecting shafts
„ Driver called worm looks like a thread

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 Rack and pinion
„ A rack is a gear whose pitch diameter is
infinite, resulting in a straight line pitch circle.
„ Involute of a very large base circle approaches
a straight line
„ Used to convert rotary motion to straight line
motion
„ Used in machine tools

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Fig. 11.7 Rack and pinion Rack and pinion

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Internal spur gear Internal spur gear

„ Provides more compact drives compared to
external gears
„ They provide large contact ratio
„ Relatively less sliding and hence less wear
compare to external gears

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 Internal spur gear Internally Meshing Spur Gears

Figure 14.14 Internally

meshing spur gears.

©1998 McGraw-Hill, Hamrock,

Jacobson and Schmid
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Gear Assemblies Fig. 11-

11-9 Velocity Ratio

„ Identified based on the input and output shaft

positions

Parallel shaft Perpendicular Other types

shaft
Spur gears Bevel and Miter Rack-
Rack-and-
and-pinion
Helical gears gears Ng Dg
Cross-
Cross-helix Vr = =
Np Dp
Worm gears
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Velocity Ratio Velocity Ratio

Ng Dg
„ Velocity ratio is defined as the ratio of „ Vr = Velocity ratio Vr = N p = D p
rotational speed of the input gear to that of the „ Np = Number of teeth on pinion
output gear „ Ng = Number of teeth on gear
„ Dp = Pitch diameter of pinion
Ng Dg Dg = Pitch diameter of gear
Vr = = „
Np Dp

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Example Problem 11-1: Velocity Ratios and Gear Trains Example Problem 11-1: Velocity Ratios and Gear Trains
(cont’d.)
(11-1)
• For the set of four gears shown below, calculate output speed, output
torque, and horsepower for both input and output conditions and overall N2 N4
Vr = •
velocity ratio: N1 N3

60 60 9
Vr = • =
20 20 1

− Output speed:

n1
n4 =
Vr

1
3600 rpm • = 400 rpm
9

− Output torque:

T4 = T1 Vr

9
T4 = 200 in-lb • = 1800 in-lb
1

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Example Problem 11-1: Velocity Ratios and Gear Trains Example Problem 11-2: Velocity Ratios and Gear Trains
(cont’d.)

• For the gear train shown below, determine the train value, output speed,
− Input horsepower: output direction, output torque, and output power.

(2-6)

Tn
hp =
63,000

200 in-lb 3600 rpm

hp =
63,000

hp = 11.4

− Output horsepower:

1800 in-lb 400 rpm

hp =
63,000

hp = 11.4

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Example Problem 11-2: Velocity Ratios and Gear Trains Example Problem 11-2: Velocity Ratios and Gear Trains
(cont’d.)
(cont’d.)
− Direction:
– Train value: NB N N
Vr = • D • E (11-1) • If: Gear A – clockwise
NA NC ND
Gear B – counterclockwise
65 60
Vr = • = 9.75 / 1 Gear C – counterclockwise
20 20
Idler cancels out and has no effect on overall train value. Gear D – clockwise

Gear E – counterclockwise
– Output speed:
NA 3000 rpm
nE = = = 307.7 rpm
Vr 9.75 / 1 − Output power:

rev min
P = TnE = 97.5 Nm 307.5
min 60 sec
π
– Output torque:
TE = T A Vr P = 1571 Nm/sec or
J
or W
s
TE = 10 Nm (9.75 / 1) = 97.5 Nm
P = 1.57 kW
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 Spur Gears Pinion Gears

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Internal Gears Spur gear geometries

„ Pitch circle: is the imaginary circle on which most
gear calculations are made. When two gears meet
their pitch circles are tangent to each other
„ Pitch diameter (D (Dp) and pitch radius (r): These are
the diameter and radius of the pitch circle.
„ Pitch point: The point on the imaginary line joining
the centers of the two meshing gears where the pitch
circle touch
D-d
2

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Pitch circle

Figure 14.1 Spur gear drive.

©1998 McGraw-Hill, Hamrock,
August 15, 2007 47 August 15, 2007 48
Text Reference: Figure 14.1, page 616 Jacobson and Schmid

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 Spur gear geometries
„ Addendum circle: It is the circle that bounds the
outer ends of the teeth and whose center is at the
center of the gear (Fig. 7.2).
7.2).
„ Dedendum circle: It is the circle that bounds the
bottoms of the teeth and whose center is at the
center of the gear (Fig. 7.2).
7.2).
„ Addendum (a): is the radial distance from the
7.2).
pitch circle to the outer end of the teeth. (Fig. 7.2).
„ Dedendum (b): is the radial distance from the
pitch circle to the bottom of the teeth. (Fig. 7.2).
7.2).
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Spur gear geometries
„ Circular pitch (Pc): is the distance between
corresponding points on adjacent teeth measured
along the pitch circle (Fig. 7.2).
7.2).
„ Diametral pitch (Pd): specifies the number of teeth
per inch of pitch diameter.
„ Tooth space: is the space between the adjacent teeth
measured along the pitch circle (Fig. 7.2).
7.2).
„ Tooth thickness: is the thickness of the tooth
measured along the pitch circle (Fig. 7.2).
7.2).
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Spur gear geometries

„ Face width (W): is the length of the tooth measured
parallel to the gear (Fig. 7.2).
7.2). Figure 14.8 Pitch
„ Face: is the surface between the pitch circle and the and base circles
top of the tooth (Fig. 7.2). for pinion and gear
7.2).
as well as line of
„ Flank: is the surface between the pitch circle and the action and
bottom of the tooth (Fig. 7.2). 7.2). pressure angle.
„ Pressure angle (φ (φ): is the angle between the line of
action and a line tangent to the two pitch circles at the rb = r cosϕ
pitch point. (Fig.
(Fig. 14.8 Hamrock).
Hamrock).
D b = D p cosϕ
©1998 McGraw-Hill, Hamrock,
Jacobson and Schmid
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Spur gear geometries Gear terminology

„ Line of action: is the locus of all the points of
contact between two meshing teeth from the time the
teeth go into contact until they lose contact.
„ Pinion: is the smaller of the two meshing gears.
„ Backlash: is the difference (clearance) between the
tooth thickness of one gear and the tooth space of the
meshing gear measured along the pitch circle (Fig. 7.5)
7.5).
„ Clearance (c): is the addendum minus dedendum.
dedendum.
„ Working depth: is the distance that one tooth of a
meshing gear penetrates into the tooth space.
„ Base circle: is an imaginary circle about which
the tooth involute profile is developed.
„ Fillet: is the radius that occurs where the flank of
the tooth meets the dedendum circle.
„ Module: replaces diametral pitch in metric
system.

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 Basic formulas for spur gears Specifications for standard gear teeth
NP
„ Diametral pitch, Pd = Item Full depth & pitches Full depth & 14½
14½° full
DP coarser than 20 pitches finer than depth
20
π DP
„ Circular pitch, Pc = Pressure 20°
20° 25°
25° 20°
20° 14½
14½°
NP angle
1
„ Addendum, a = Addendum 1.0/ Pd 1.0/ Pd 1.0/ Pd 1/ Pd
Pd (in.)

„ Dedendum, b = 1.250
Dedendum, Dedendum
(in.)
1.250/ Pd 1.250/ Pd 1.2/ Pd + 0.002 1.157/ Pd

Pd

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Basic formulas for spur gears
0.250
„ Clearance, c = b – a =
Pd
„ Where
„ Dp = pitch diameter of pinion
„ Np = number of teeth on the pinion
„ It can be shown that
Pd × Pc = π
Basic formulas for spur gears
„ Center to center distance
D + D pp Ng + Np
„ CtoC = pg =
2 2 Pd
„ Where
„ Dpp = pitch diameter of pinion
„ Np = number of teeth on the pinion
„ Dpg = pitch diameter of gear
„ Ng = number of teeth on the gear
„ Pd = Diametral pitch

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Metric System Metric System

1 1
„ Module (m) = Pd „ Diametral pitch, Pd =
m
See Table 11.1 for equivalents
„
„ Circular pitch, Pc = π m
„ Normally they are not converted
„ Addendum, a = m
„ Dedendum,
Dedendum, b = 1.25 m

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 Inch units Metric units
„ A spur gear of the 14 ½ degree involute system „ A spur gear of the 14 ½ degree involute system
has 32 teeth of diametral pitch 8. Find has a module of 8 mm and 35 teeth. Find
„ The pitch diameter „ The pitch diameter
„ The circular pitch „ The circular pitch
„ The outside diameter (addendum diameter) „ The outside diameter (addendum diameter)

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Example Problem 11-3: Pressure Angle

• For the set of gears shown in Figure 11-17, if diametral pitch is 8, find the pitch
Example Problem 11-3: Pressure Angle (cont’d.)
diameter, circular pitch, and shaft center-to-center distance.
• The pinion has 16 teeth and the gear has 32 teeth.

− Centerline distance:
− Pitch diameter:
(11-4)
Dp =
Np
or
Ng (11-2)
Pd Pd

− Pinion: Dp Dg Np + Ng
C-C = + or C - C =
Dp =
16
= 2 inches
2 2 2Pd
8

− Gear: 16 + 32
32 C-C =
Dp = = 4 inches 2 (8)
8

− Circular pitch: C – C = 3 inches

(11-3)
π Dp
Pc =
Np
• Circular pitch would be the same
π 2 in
Pc =
16
= .393 inch for both pinion and gear.
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 Summary
„ To understand the gears one should be familiar with the
gear terminology.
„ Spur gears are most commonly used for transmission of
power.
„ Speed of mating gears is inversely proportional to the
number of teeth.
„ Mating gears should have the same diametral pitch.
„ A number of gear manufacturing methods are available.
„ Good gear design should take care of the power, speed, life
and material properties.

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