Lctrgaermit

2.
72 Elements of
Mechanical Design
Lecture 5
Gears
ofAll
Justin
Image
Martin courtesy
Culpepper,
rightsLai
reserved
Lecture structure
Motivation and overview of gear types
Gear kinematics
Serial gear trains (special case: planetary gear trains)
Gear manufacturing
Gear failure: Bending
Gear failure: Contact
Martin Culpepper, All rights reserved
Motivation
In your lathe: ???
Critical to understand this machine element and have

it in your toolbox
Geared mechanisms
Gears transmit power across rotating shafts
Gears can NOT increase power
Power loss during transmission in real gears
Input
Gears are used for:

Changing direction of rotation
Changing torque
Changing rotational speed
Output
Gear design/selection based on

How are the shafts/gears arranged?
Gear kinematics
How much power is transmitted?
Failure strength
Gears at all scales
Microgear with pollen and red blood

cells
Courtesy of Sandia National Laboratories,

SUMMiT(TM) Technologies,
www.mems.sandia.gov
South Bend lathe change gears
Tractorbynet.com
Pocket watch movement
http://www.timezone.com/library/workbench/w
orkbench631678210214858916
Tamiya dual gearbox
http:// www.pololu.com
Cage gear for material processing plant
http://www.cage-gear.com
Very Large Array radio telescopes
Wikimedia commons
Gear types
Axes of rotation dont have to be parallel!

Parallel shafts
Spurs, helical
Intersecting shafts
Bevel gears
Neither parallel nor intersecting

Hypoids (some sliding contact), spiral bevel, worm
Gear types and purposes

Spur gear set
Teeth parallel to axis of rotation
Only good for parallel shafts
Simple shape = simple design and low cost
Noise is sensitive to errors in tooth shape
Spur Gears
Helical gear set

Teeth inclined to axis of rotation
Gradual engagement of teeth = low noise
Shaft may or may not be parallel
Thrust (axial) loads from teeth reaction forces
High speed and high power transmission
Tooth-tooth contact force pushes gears around
(rotate) & apart along axis
Helical Gears
More gear types and purposes

Bevel gear set
Teeth formed on conical surface
Used between parallel or non-parallel shafts (hypoid)
For non-parallel shafts, shaft axes intersect at some point
Teeth can be straight or spiral away from axis of rotation
Worm gear set

Very low transmission ratios (output divided by input)
Worm is input and gear is output
Sliding between worm-gear leads to high friction losses
Non-parallel, non intersecting shafts
Bevel Gears
Worm Gear
Worm Gear Set
Rack and pinion set

Rack teeth may be straight or angled w.r.t rack motion
Good means to transmit between rotary and linear motion
Rack & Pinion 9
Gear kinematics:
Getting the motions we want
What form of motion do we want?

Want uniform rotary motion
Conjugate action: constant angular velocity ratio
Key to conjugate action: use an involute tooth profile
Output speed of gear train

Reality: small imperfections and
bending
of gear teeth result in some variation
Assume
constant
out,
Constant speed
Ideal involute/gear
in
[rpm]
Non or poor involute
time [sec]
11
Consequences of conjugate action

Rolling cylinders (No slip between cylinders)
Circles share common point traveling at velocity:
r1
r2
1
2
Pitch circle:
r2
r1
Circle that passes through pitch point

Pitch Circles Meet @ Pitch Pt.
r2
r1
r1
r2
v
Pitch Circle 1
Pitch Circle 2
12
Instantaneous velocity and pitch

Meshing gears must have same pitch!
Ng = # of teeth, Dp = Pitch circle diameter
Diametral pitch, PD:
Circular pitch, PC:
PD
PC
Ng
Dp
D p
Ng
(Used for inch system, given as TPI)
PD
Metric system uses module

Inverse of , units of
mod 2 gear or mod 0.5

wikipedia
No metric gears from McMaster?

13
Drawing the involute profile

To draw a gear: specify the pitch circle diameter and
pressure angle,
Common pressure angles: 20,
22.5, 25
Line of
Action
Older, less used: 14.5
RB
RP cos
Pitch Circle
Pitch Point
Base Circle
Mach. Handbook, 28th ed
RB
RP
14
Drawing the involute profile

Pitch Point
Pitch Circle
Unwrap a taut string

wound on the base circle
L3
L2
3
2
1
L1
Ln
nRB
Keep string tangent to base
circle
Radius varies continuously
Base Circle
RB
15
Contact ratio
Addendum (pinion)
Mc
Line of
Action
qt
p
Mc = Contact ratio
qt = arc of action
p = circular pitch
Lab = Length of line of action
Pitch Circle
Mc
Addendum
(gear)
Pitch Point
Lab
p cos
Mc > 1.2
(Shigley)
Base Circle
Power transmission:
1.4 minimum
16
Contact ratio: close-up

Mc
qt
p
Mc = Contact ratio
qt = arc of action
p = circular pitch
Lab = Length of line of action
Mc
Lab
p cos
Mc > 1.2 in order
to ensure
continuous
contact
Power transmission:
1.4 minimum
17
Interference: non-conjugate contact

2k
2
2
NP
m
m (1 2m) sin
2
1 2m sin
Variables
Np = Minimum number of teeth that can exist without interference
k = 1 for full depth teeth
k = 0.8 for stub teeth
= Pressure angle
m = Ratio of the # of teeth on the gear to # of teeth on the pinion
If m = 4 and = 20, then = 16 teeth

A 16 tooth pinion will mesh with a 64-tooth gear without interference
Any smaller gear set with m = 4 will have interference
If m = 1, = . =
If m = 1, = =
18
Interference: diagram
19
Serial gear train

kinematics
Transmission ratio for serial gears

A gear train consists of two or more gears in mesh
Power in: Tin
TR
sign
Gear train
in
out
in
...
out
1
in
From pitch equation: P1
out
in
N1
D1
N2
D2
Power out: Tout
out
Important: take direction of rotation into account! (sign)

n
P2
D1
D2
N1
N2
For Large Serial Drive Trains:
TR
Product of driving teeth

proper sign
Product of driven teeth
out
in
21

Serial trains:
Example 1:
TR

out
in
10
TR ?
20
in
proper sign
out
Example 2:
driven
drive
driven
drive
20
in
20
TR ?
driven
drive
10
10
out
22

Serial trains:
Example 1:
TR
10

TR
20
in
proper sign
TR
out
Example 2:
driven
drive
20
10
TR
N1
N2
20
in
20
driven
drive
10
10
in
N1
N2
TR
driven
drive
20
10
out
10
10
N2
N3
10
20
N3
N4
out
23

Example 3: Integral gears in serial gear trains
Gears 2 & 3 are one piece, they rotate together about the same axis
What is TR if Gear 1 = input and 5 = output?
TR
proper sign
OUT
Gear 1
N1 = 9
Gear 2
N2 = 38

33
Gear 3
N3 = 9
Gear 4
N4 = 67
Gear 5
N5 = 33
67
9 IN
9
38
24

Example 3: Integral gears in serial gear trains
Gears 2 & 3 are one piece, they rotate together about the same axis
(same angular velocity)
What is TR if Gear 1 = input and 5 = output?
TR
proper sign

OUT
N4
N5
9
38
9
67
Gear 5
N5 = 33
0.065
33
Gear 3
N3 = 9
Gear 4
N4 = 67
67
33
Gear 1
N1 = 9
Gear 2
N2 = 38
N3
N4
N1
N2
67
9 IN
9
38
25
Planetary gear train

kinematics
Planetary gear trains

Planetary gear train is analogous to a solar system
Small & large TRs in a compact mechanism
Legend:
Planet
gear
Ring
gear
Planet
gear
Arm
2
Sun
gear
Planet
gear
27
Planetary gear train animation

Ring
gear
Train 1
How to find TR?

2-stage animation
Arm
Planet
gear
Sun
Train 2
Ring
gear
Arm
Planet
gear
Sun
28
Planetary gear train TR

If we make the arm stationary,
then this is a serial gear train:
Sun Gear
Planet Gear
Ring Gear
ra
ring
arm
sa
sun
arm
TR
Arm
N sun N planet
N planet N ring
pa
planet
sa
sun
TR
TR
arm
N sun
N ring
TR
arm
N sun
N planet
29
Planetary gear train TR

If the sun gear is the input, and
the ring gear is held fixed:
Sun Gear
Planet Gear
Arm
Ring Gear
ra
sa
sun
TR
output
arm
TR
arm
N sun N planet
N planet N ring
arm
N sun
N ring
TR
sun
TR 1
30
Gear manufacturing
Gear manufacturing - Hobbing
32
Gear manufacturing - Hobbing
33
Gear manufacturing - Shaping
34
Other manufacturing techniques

Cold processes
Cold drawing
Work hardening
Cold rolled
Smooth, work hardened surfaces
Hot processes
Sintering
Sintered iron gears in appliances, run quietly, can hold lubricant
Injection molding (polymers)

Die casting
Low temp. melting materials -> less load capacity
Extruded
35
Selection vs. design of gears

Why do we care about gear tooth surface finish
What affects the finish on the gear surfaces?
How good could it be?
How much would it cost?
Why do we care about the tooth geometry at the root

What affects the quality of the fillet at the root?
How good could it be?
How much would it cost?
36
Gear failure
Gear failure
Failure modes
Bending failure (e.g. root stresses)
Contact fatigue (e.g. pitting)
Root
bending
failure
Failure analysis
Estimating bending/contact stresses
Estimating allowable stresses
Analysis approaches
Lewis bending equation
AGMA (American Gear Manufacturers Association)
Pitting
38
Photoelasticity: Visualizing stress

Bending
Contact
39
AGMA approach: Calculating stresses

bending
contact
Pd K m K B
Wt K o K v K s
(U .S . units)
F J
Cp
Km C f
Wt K o K v K s
(U .S . units)
dp F I
Incredibly uninteresting, plug-chug & non-scientific

40
Gear failure
at the root:
Bending stress
Bending root stress

Lewis bending equation (1892)
Model tooth as cantilever
Estimate bending stress near the root
Mc
I
Wt P
FY
6 Wt L
F t2
P: Diametral pitch (1/module)

Y: Lewis form factor
~ to for = 20o
f( # of teeth )
Conservative estimate
Implies that one tooth carries the load
Heaviest load occurs mid-tooth, not at root

42
Root stress: dynamic effects

How to incorporate dynamic effects
One way of addressing
a V
a
Kv
V = pitch line velocity

Kv depends on fabrication (since a, b, c do too)
For rough estimates
Wt P
KV
FY
This is for English units, for SI is different
43
Allowable bending stress

These types of plots are associated with conditions
St
H b Ct
44

all
St YN
(U .S . units)
S F KT K R
all
St YN
( SI units)
S F Y YZ
Elements of the equations:

St
YN
KT
KR
SF

Stress cycle life factor
Temperature factors
Reliability factors
AGMA factor of safety
Allowable stresses for:

Unidirectional loading
10 million stress cycles
99 percent reliability
45
Gear failure
at the surface:
Contact (Hertzian)
stress
High cycle failure: Pitting
47
Avoiding high cycle failure: Stress variables

Equivalent modulus
1
Ee
2
2
1 v1 1 v21
E1
E2
Hertzian contact analysis:

line contact
Half contact width
Watch out! The book

switches meaning of F here
(applied force or face width?)
2Wt d1 d 2
L Ee d1 d 2
0.5
0.333
Maximum contact pressure
2Wt
bL
48
Allowable contact stress [ANSI/AGMA 2001-D04 and 2101-D04]

Sc
H b Cc
49
Allowable contact stress

c , all
SC Z N C H
(U .S . units)
S H KT K R
c , all
S C Z N ZW
( SI units)
S H Y YZ
Elements of the equations:

SC
ZN
CH
KT
KR
SH
Allowable contact stress

Stress cycle life factor
Hardness ratio factors for pitting resistance
Temperature factors
Reliability factors
AGMA factor of safety
Allowable stresses for:

Unidirectional loading
10 million stress cycles
99 percent reliability
50
Summary
Summary
Gear types
Conjugate action
For uniform speed
Transmission ratio
Serial & planetary train
Gear manufacturing
Performance vs. cost
Failure
Bending vs. contact failure
52
Design Recommendation
Iteration required!
Program design equations into your favorite analytical software (Excel,
MathCAD, MATLAB, etc)
Excel: you can link values from your design table to Solidworks
dimensions. Learn how to do this!
How are you mounting your gears? Here be dragons

Dont forget to consider the reaction forces from the gears on the rest of
the structure!
CAD: model with addendum, dedendum, and pitch diameter use P.D. for
mating, the others for interference checking (addendum in particular)
53
References
J Shigley, C. Mischke, R. Budynas, K. Nisbett. Shigleys Mechanical
Engineering Design.
ASM International. Gear Materials, Properties, and Manufacture. Materials
Park, Ohio 2005
D. W. Dudley. Handbook of practical gear design. McGraw-Hill 1984

K. L. Johnson. Contact Mechanics. Cambridge University Press 1985
E. Oberg, F. D. Jones, H. L. Horton, and H. H. Ryffel. Machinerys Handbook.
28th ed. Industrial Press, New York 2008
P. Lynwander. Gear Drive Systems: Design and Application. Marcel Dekker Inc,
New York 2003.
54
Appendix A: Spur gear nomenclature
Mach. Handbook
55

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2.

Critical to understand this machine element and have

Martin Culpepper, All rights reserved

Gears are used for:

Gear design/selection based on

Martin Culpepper, All rights reserved

Gears at all scales

Microgear with pollen and red blood

Courtesy of Sandia National Laboratories,

South Bend lathe change gears

Pocket watch movement

Tamiya dual gearbox

Cage gear for material processing plant

Very Large Array radio telescopes

Axes of rotation dont have to be parallel!

Neither parallel nor intersecting

Martin Culpepper, All rights reserved

Gear types and purposes

Helical gear set

Martin Culpepper, All rights reserved

More gear types and purposes

Worm gear set

Worm Gear Set

Rack and pinion set

Rack & Pinion 9

What form of motion do we want?

Output speed of gear train

Non or poor involute

Consequences of conjugate action

Circle that passes through pitch point

Instantaneous velocity and pitch

(Used for inch system, given as TPI)

Metric system uses module

mod 2 gear or mod 0.5

Martin Culpepper, All rights reserved

No metric gears from McMaster?

Drawing the involute profile

Older, less used: 14.5

Mach. Handbook, 28th ed

Martin Culpepper, All rights reserved

Drawing the involute profile

Unwrap a taut string

Martin Culpepper, All rights reserved

Martin Culpepper, All rights reserved

Contact ratio: close-up

Martin Culpepper, All rights reserved

Interference: non-conjugate contact

If m = 4 and = 20, then = 16 teeth

Martin Culpepper, All rights reserved

Serial gear train

Transmission ratio for serial gears

Power in: Tin

From pitch equation: P1

Power out: Tout

Important: take direction of rotation into account! (sign)

For Large Serial Drive Trains:

Product of driving teeth

Martin Culpepper, All rights reserved

Transmission ratio for serial gears

Product of driving teeth

Martin Culpepper, All rights reserved

Transmission ratio for serial gears

Product of driving teeth