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n
i
i i
R b C W
$
!
$
3$2
where C is a constant of proportionality whose value depends on the units of measure
used for the various quantities. The odd subscripts 3
! $ j i
, for
n j ,..., 0 , $ , !
2 refer to
the pinions, while the even subscripts 3
j i $
, for
n j ,..., 0 , $ , !
2 refer to the larger gears
in the meshing pairs of gear.
Fig. , I##ust%ation of stage gea% %atio and o$e%a## gea% %atio
!
!
G
0
$
G
7
! $
n
n
G
n $
2n!
2n
1ote that in Fig. ,5
n i
i i
..., , 4 , 0 , $ (
! $ $ $
Moreover, the overall gear ratio is defined as follows5
!
$
n
G
%n accordance with the bloc# diagram in Fig. ,, the overall gear ratio
2 3G
, which is
predetermined and therefore constant for a given gear train, is5
0 of 6
Gear Ratios for Compound Gear Trains of Minimum Weight
n
j
j n j
G G G G G G
!
$ !
302
where
2 3
j
G
denotes the gear ratio at the
th j
stage of the gear train.
The problem of weight minimi/ation is symmetrical in that it does not matter which end
of the gear train is regarded as the input end. However, in most practical applications, the
gear train is a speed reducer, therefore the pinion is the driver. %n such cases, it follows
that5
n j
R
R
G
j
j
j
..., , 0 , $ , ! (
$
! $
342
The normali/ed relative weight is now defined as follows5
$
!
$
!
R b C
W
W
n
372
.rom equations 3$2 and 372, it follows that5
1
]
1
n
i
i i
n
R b
R b
W
$
!
$
!
$
!
$ $
382
1ow, in accordance with equation 342, the following can be written5
,
_
,
_
j
j
j
j j j
G R
R
R
R
R
R
R
R
!
!
! $
! $
$
!
! $
!
$
392
Moreover, in accordance with equation 3!2, the following can be written5
!
! $
!
$
b
b
b
b
j j
3:2
Moreover, equation 382 may be re;written as follows5
1
1
]
1
,
_
,
_
n
j
j j j j
n
R
R
b
b
R
R
b
b
W
!
$
!
$
!
$
$
!
! $
!
! $
362
.rom equations 392, 3:2 and 362, it follows that5
'
1
1
]
1
,
_
,
_
n
j j
j j
n
G R
R
b
b
W
!
$
$
!
! $
!
! $
!
!
3!<2
1ow the minimi/ation problem may be formally stated as follows5
4 of 6
Gear Ratios for Compound Gear Trains of Minimum Weight
'
1
1
]
1
,
_
,
_
n
j
j
n
j j
j j
n
G G
G R
R
b
b
W
!
!
$
$
!
! $
!
! $
<
!
!
constraint the to sub=ect
Minimi/e
)n using the Lagrange multiplier
2 3
, the following function may be considered whose
relevant partial derivatives will be /ero when
n
W
is minimum 4"5
G W F
n
+
3!!2
Hence the following5
j
j j
j
j
G
G
R
R
b
b
G
G
F
+
,
_
,
_
,
_
$
!
! $
!
! $
0
$
<
or5
n j
G
R
R
b
b
G
j j
j
..., , 0 , $ , ! (
$
!
constant a
$
!
! $
!
! $
$
,
_
,
_
,
_
3!$2
)n letting
! j
in equation 3!$2, one obtains the following5
constant a
$
!
$
!
,
_
G
G
3!02
.rom equations 3!$2 and 3!02, the following e,pression can be obtained, which, within
the assumptions made in this analysis, is a statement of the condition for
n
W
to be
minimum5
n j
G
G
R
R
b
b
j j j
..., , 0 , $ , ! (
$
!
$
!
! $
!
! $
,
_
,
_
,
_
3!42
-quation 3!42 may be re+written in terms of pitch circle diameters, as follows5
n j
G
G
D
D
b
b
j j j
..., , 0 , $ , ! (
$
!
$
!
! $
!
! $
,
_
,
_
,
_
3!4a2
, DISCUSSION
,.1 Inte%p%etations of t"e so#ution
'y using equation 3!2 it can be deduced that5
$
$
!
$
!
! $
b
b
b
b
b
b
j j j
3!72
7 of 6
Gear Ratios for Compound Gear Trains of Minimum Weight
Moreover, by using equation 342, it can be deduced that5
$
!
!
$
! $
hence ,
R
R
G
R
R
G
j
j
j
,
_
,
_
,
_
,
_
j
j
j
j j
R
R
R
R
R
R
R
R
G
G
$
$
!
! $
!
$
$
! $
!
3!82
.rom equations 3!42, 3!72 and 3!82, the following can be readily obtained5
$
$
$
$
!
! $
$
!
! $
$
$
,
_
,
_
,
_
,
_
j
j j j
R
R
R
R
R
R
b
b
$
$
$
$
$
,
_
,
_
j
j
R
R
b
b
$
$ $
$
$ $ j j
R b R b
Multiplying both sides of the above e,pression by the number yields the following5
n j R b R b
j j
..., , 0 , $ , ! ( constant a
$
$ $
$
$ $
3!92
Thus, within the assumptions made in this paper, the gear train will be of minimum
weight if the volumes of the blan#s of the larger gear wheels in all the meshing pairs of
gear wheels are made equal. This interpretation of the solution has an intuitive appeal.
-quation 3!92 may be re+written in term of the pitch circle diameters, as follows5
n j D b D b
j j
..., , 0 , $ , ! ( constant a
$
$ $
$
$ $
3!9a2
Alternatively, equation 3!42 may be re+written as follows5
$
!
$
!
$
$
$
! $
!
! $
,
_
,
_
,
_
,
_
G
G
R
R
R
R
b
b
j j
j
j j
3!:2
.rom equations 342, 3!72 and 3!:2, the following can be readily obtained5
$
!
$
$
!
$
!
$
,
_
,
_
,
_
G
G
G
R
R
b
b
j
j
j j
$
!
$
!
$
!
$
!
,
_
,
_
,
_
G R
R
b
b
j j
8 of 6
Gear Ratios for Compound Gear Trains of Minimum Weight
$
$ $
$
!
$
! ! j j
R b G R b
Multiplying both sides of the above equation by yields the following5
( ) n j R b G R b
j j
..., , 0 , $ , ! ( constant a
$
$ $
$
!
$
! !
3!62
-quation 3!62 may be re+written in term of the pitch circle diameters, as follows5
( ) n j D b G D b
j j
..., , 0 , $ , ! ( constant a
$
$ $
$
!
$
! !
3!6a2
Thus, within the assumptions made in this paper, the gear train will be of minimum
weight if the volumes of the blan#s of the larger gears in all the meshing pairs of gear
wheels are made equal to the volume of the >first? pinion in the gear train divided by
$
!
G . This interpretation too has an intuitive appeal.
,.2 T"e !ase of a gea% t%ain -it" !onstant fa!e -idt"
The face width
2 3b
of gear teeth is not standardi/ed but according to @uvinall 7" it is
common practice to adopt the range m b m !4 6 < < , where m is the module. %t is feasible
that in some applications all the gear wheels that comprise a gear train may be of equal
face width. %mposing this constraint onto equation 3!92, results in the following5
n j R R
j
..., , 0 , $ , ! ( constant a
$ $
3$<2
-quation 3$<2 may be re+written in term of the pitch circle diameters, as follows5
n j D D
j
..., , 0 , $ , ! ( constant a
$ $
3$<a2
,., T"e !ase of a gea% t%ain -it" !onstant fa!e -idt" and !onstant pinion %adii
%f in addition to the face width being constant throughout the gear train, the radii of all the
pinions are made equal, then from equation 3$<2, the following can be obtained5
n j G G
R
R
R
R
j
j
j
..., , 0 , $ , ! ( constant a
!
$
!
$
! $
n j G G
n
j
..., , 0 , $ , ! ( constant a
3$!2
-quation 3$!2 is a statement of the result that was obtained by .a/e#as 302 when he
assumed a gear train of constant face width, pinion radii and module. However, the
assumption of constant module appears to have been unnecessary, as it has not been made
anywhere in this paper. %n fact, gear ratio is not a function of the module. Therefore, in
9 of 6
Gear Ratios for Compound Gear Trains of Minimum Weight
an attempt to minimise gear train si/e and weight through manipulation of gear ratios, the
module, as such, should be of no relevance.
. CONCLUSIONS
Aithin the assumptions made in this paper, minimum weight of a compound gear train of
arbitrary number of stages will be achieved if5
!. The volumes of the blan#s of the larger gears in all the meshing pairs of gear wheels
are made equal. This result has an intuitive appeal.
$. The volumes of the blan#s of the larger gears in all the meshing pairs of gear wheels
are made equal to the volume of the blan# of the >first? pinion in the gear train
divided by
$
!
G , where
!
G
is the gear ratio of the first stage. This result too has an
intuitive appeal.
0. .or the case of a gear train in which the face widths are equal throughout, the gear
train will be of minimum weight if the pitch radii of all the larger gear wheels are
made equal.
4. .or the case of a gear train in which the radii of all the pinions are equal, given that
the face widths are equal throughout, the train will be of minimum weight if the gear
ratios of all the stages are made equal.
R/F/R/NC/S
!. HB1T, C)11-LL &. and L-DT-& A. GA&E-& 3!6902. Fa%m 0a!"ine%'
0e!"anisms( chapter !$. The %owa Dtate Bniversity Fress, Ames %owa, BDA.
$. &A1-G, &BDD-LL &. and HA&L C. 'BTL-& 3!676). Criteria for the Design and
Development of Farm Euipment. Agricultural -ngineering .1302( pp.!09+!4!.
0. .AI-HAD, G. A. 3!6972. !ptimal "peed Ratio of Constant #it$h Gearing.
Transactions of the ADM-, Deries '( @ournal of -ngineering for %ndustry 23342.
4. G&)DDMA1, DTA1L-G L. 3!6992. Ca#!u#us( chapter !:. Academic Fress. 1ew
Gor#, Dan .rancisco and London.
7. @BE%1ALL, &)'-&T *. 3!6:02. Fundamenta#s of 0a!"ine Component Design(
chapter !7. @ohn Ailey and Dons. 1ew Gor#, *hichester, 'risbane, Toronto, and
Dingapore.
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