2 Gears PDF

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. Fundamentals of Gears
Ratna Kumar Annabattula
208, Machine Design section

Department of Mechanical Engineering
IIT Madras
Office hours: Wednesday, 3:00 p.m. - 4:00 p.m.

email: ratna@iitm.ac.in
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Ratna Kumar (IIT Madras) Fundamentals of Gears July-Nov 2017 1 / 67
Outline I
1. Types of Gears
.
2 Nomenclature
3. Fundamentals
Conjugate Action
Involute Properties
Contact Ratio
Interference in Meshing
Forming of Gear Teeth
Bevel Gear Terminology
Parallel Helical Gears
Tooth Systems
Gear Trains
4. Force Analysis
Spur Gears
Helical Gears . . . . . . . . . . . . . . . . . . . .
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Types of Gears
Types of Gears I
Spur gears have teeth parallel

to the axis while helical gears
have teeth inclined to the axis
Both are used for transmitting
(a) Spur Gears power between parallel shafts
Helical gears are less noisy due
to gradual engagement of teeth
Helical gears develop thrust
loads and bending couples
unlike spur gears
(b) Helical Gears

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Types of Gears
Types of Gears II
Bevel gears: Teeth formed on

a conical surface
Bevel gears transmit power
between intersecting shafts
Straight tooth and spiral bevel
gears
(c) Bevel Gears

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Types of Gears
Types of Gears III
Transmit rotary motion

between two non-parallel and
non-intersecting shafts
Typically used for very high
speed ratios (≥ 3)
(d) Worm Gears
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Nomenclature
Nomenclature of Spur Gear I
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Nomenclature
Nomenclature of Spur Gear II
Pitch circle is an imaginary circle

All calculations are based on pitch circle diameter (d)
Pitch circles of two mating gears are tangential to each other
Smaller gear is called pinion and the larger is called gear
Circular Pitch (p): distance measured on the pitch circle from a
point on one tooth to the corresponding point on the next tooth
Circular pitch (p) = tooth thickness + width of space
M odule: m = dz , where d is the pitch diameter and z is the number
of teeth. It gives an indication to the tooth size.
Diametral pitch: P = dz , i.e, P = 1/m.
Diametral pitch is used only with U.S. units, as number of teeth
per inch
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Nomenclature
Nomenclature of Spur Gear III
Addendum, a: radial distance between the top land (addendum

circle) and the pitch circle
Dedendum, b: radial distance between the bottom land
(dedendum circle) and the pitch circle
Clearance circle: tangent to the addendum circle of the mating
gear
clearance c: dedendum of the gear - addendum of the mating gear
backlash: width of tooth space measured on pitch circle - thickness
of the engaging tooth measured on pitch circle
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Nomenclature
Nomenclature of Spur Gear IV
d
m =
z
z
P =
d
πd
p = = πm
z
pP = π
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Fundamentals Conjugate Action
Conjugate Action I
Conjugate action refers to
transmission of constant
angular velocity ratio during
meshing
Involute profiles display
such a property
c is the point of contact
Line ab is the line of action
Line of action intersects with
the center-center line O − O at
P
The angular velocity ratios is
inversely proportional to their
radii to the point P
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Fundamentals Conjugate Action
Conjugate Action II
Circles drawn through P called pitch point are called pitch circles
To transmit motion at constant angular velocity, the pitch point P
must remain fixed
In other words, all the lines of action for every instantaneous point
of contact must pass through the same point P.
For involute profiles,all points of contact occur on the same
straight line ab.
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Fundamentals Involute Properties
Involute Properties I
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Involute Properties II
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Fundamental law of gearing
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When two gears are in mesh, their pitch circles roll on one another
without slipping
Let’s say, pitch radii r1 and r2 and the angular velocities ω1 and ω2
The pitch line velocity is
V = ω1 r1 = ω2 r2 =⇒
ω1
ω2
=
r2
r1
J
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The common normal to the tooth profiles at the point of contact
must pass through a fixed point (i.e., the pitch point) on the line
of centers (to get constant velocity ratio)
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Involute Properties III

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Advantages of an Involute Profile
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Conjugate action is maintained between a pair of involutes.
Pressure angle (ϕ) is maintained constant.
Conjugate action is guaranteed even if the center distance is
altered.
Ease of manufacturing: gears are produced by the process of
generation using a straight rack cutter.
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Involute Profile Standards
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Pressure angle (ϕ) is 20◦
addendum (a)= module (m)
dedendum (b) = 1.25 m
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Involute Properties IV
angle of action =
angle of approach +
angle of recess
line ab is called line
of action
Radial line drawn
from the
intersection of
involute profile
(through points a
and b) with pitch
circle to the center
gives angle of
approach and
recess.
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Involute Properties V
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Sample Motion of Spur Gear
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Involute Properties VI
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Cutting of involute tooth with a rack cutter
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Involute Properties VII

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Involutometry
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Involute Properties VIII

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Involutometry
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ρ = rb tan ψ = AB = rb (α + ψ)
=⇒ α := inv(ψ) = tan ψ − ψ
Further
√ √
ρ= r2 − r2b = r2b (1/ cos2 ψ − 1)
Here, rb → ∞ represents a straight line for the base circle. Hence, from
the above relation, ρ → ∞ as rb → ∞, indicating that the profile BC is
a straight line.
Hence, one can use a straight rack cutter to produce an involute tooth
profile
. as it shows conjugacy.
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Involute Properties IX
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Example Problem
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A gear set consists of a 16-tooth pinion driving a 40-tooth gear. The
diametral pitch is 2, and the addendum and dedendum are 1/P and
1.25/P, respectively. The gears are cut using a pressure angle of 20◦ .
Compute the circular pitch, the center distance, and radii of the
base circles.
In mounting these gears, the center distance was incorrectly made
1/4 inch larger. Compute the new values of pressure angle and
pitch-circle diameter.
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Involute Properties X
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Solution
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(a)
Diametral pitch: P = 2,
Circular pitch: p = π/P = π/2 = 1.57 in.
Pitch diameter of the pinion: dP = zP /P = 16/2 = 8 in
Pitch diameter of the gear: dG = zG /P = 40/2 = 20 in
The center distance: OP OG = (dP + dG )/2 = 14 in
The base circle radii rb = r cos ϕ, where ϕ is the pressure angle.
Base circle radius of the pinion:
rbP = (dP /2) cos ϕ = (8/2) cos 20◦ = 3.76 in
Base circle radius of the gear:
rbG = (dG /2) cos ϕ = (20/2) cos 20◦ = 9.40 in
.
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Involute Properties XI
(b)
Designate new diameters of pinion and gear as d′P and d′G ,
respectively with an increase in center distance of 1/4 in and hence
(d′P + d′G )/2 = 14.25 in
Due to conjugate action, the velocity ratio doesn’t change and

hence the diameter ratio remains constant
d′P /d′G = 8/20
Solving, the above two equations, we get
d′P = 8.143 in, d′G = 20.357 in.
We have rb = r cos ϕ and hence for the pinion,

ϕ = cos−1 (rbP /r′P ) = cos−1 (3.76/(8.143/2)) = 22.56◦
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Fundamentals Contact Ratio
Contact Ratio I
Arc of action qt = Arc of approach qa + Arc of recess qr

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Contact Ratio II
Consider a case of arc of action being equal to circular pitch:
qt = p
qt = p means that one tooth and its width will occupy the space AB
When a pair of tooth just begins the contact at a, another pair ends
the contact at b
At any point of time there is exactly one pair of teeth in contact
Consider a case of qt = 1.2p
When a pair of tooth begins contact at a another pair would not
have reached b
For a short period of time, both the pairs will be in contact one in
the vicinity of A and another in the vicinity of B
Contact ratio: Average number of tooth pairs in contact.
mc =
qt
p
J
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Contact Ratio III
Contact ratio is also equal to the length of path of contact divided

by the base pitch
Base pitch pb = p cos ϕ
Hence, with Lab as the length of path of contact, the contact ratio
is also given by
mc =
Lab
p cos ϕ
J
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Fundamentals Interference in Meshing
Interference I
Interference in a gear pair

◦
cut with 14 12 pressure an-
gle.
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Interference II
Contact of non-conjugate tooth pairs is called interference.

Initial point of contact: A
Final point of contact: B
The points of tangency to the base circles C and D falls within the
points A and B
Hence, interference is present
Non-involute portions are removed by the cutting tool during
manufacturing (generation process) called under cutting
Under cut teeth are relatively weak
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Interference III
Let ZP : smallest number of teeth on a spur pinion and gear

(one-to-one gear ratio) which can exist without interference.
This number of teeth for spur gear is given by
( √ )
2k
ZP = 1 + 1 + 3 sin ϕ ,
2
3 sin2 ϕ
where k = 1 for full-depth teeth and k = 0.8 for stub teeth.

For a 20◦ pressure angle, with k = 1
ZP = 12.3 = 13 teeth
Thus, 13 teeth on pinion and gear are interference-free.

◦
For a 14 12 pressure angle, ZP = 23.
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Interference IV
If the mating gear has more teeth than the pinion, i.e.,
mG = ZG /ZP > 1, then the smallest number of teeth on pinion ZP
is given by
( √ )
2k 2 + (1 + 2m ) sin2 ϕ
ZP = m G + m G
(1 + 2mG ) sin2 ϕ G
The largest gear for a specified pinion without interference is
Z2P sin2 ϕ − 4k2

ZG =
4k − 2ZP sin2 ϕ
For a 13-tooth pinion with a pressure angle ϕ = 20◦ ,
132 sin2 20◦ − 4(1)2

NG = = 16.45 = 16
4(1) − 2(13) sin2 20◦ . . . . . . . . . . . . . . . . . . . .
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Interference V
Interference can be reduced by increasing the pressure angle

resulting in small base circle.
Smaller base circle results in more of the tooth profile to be
involute.
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Fundamentals Forming of Gear Teeth
Forming of Gear Teeth
Milling
Shaping
Hobbing
Finishing
Shaving
Burnishing
Grinding
Lapping
Self Study 13.8 from Shigley’s book

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Fundamentals Bevel Gear Terminology
Bevel Gears Terminology
ZP ZG
tan γ = , tan Γ =
ZG ZP
The shape of the teeth when pro-
jected on the back cone looks like
spur gear teeth. The fictitious
number of teeth is given by
2πrb
Z′ = ,
p
where p, the circular pitch is

measured at the large end of the
teeth.
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Fundamentals Parallel Helical Gears
Helical Gears I
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Helical Gears II
Nomenclature
ψ: Helix angle
pt : Transverse circular pitch
pn : Normal circular pitch pn = pt cos ψ
pt
px : Axial pitch px = tan ψ
Pt
Pn : Normal diametral pitch Pn = cos ψ
ϕn , ϕt : normal and tangential pressure angle
tan ϕn
cos ψ =
tan ϕt
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Helical Gears III

Condition to avoid interference
Smallest number of teeth ZP for mG = ZG /ZP = 1
( √ )
2k cos ψ
ZP = 1 + 1 + 3 sin ϕt
2
3 sin2 ϕt
For a given gear ratio m = NG /NP , the smallest pinion
2k cos ψ [ √ ]
ZP = mG + mG + (1 + 2mG ) sin ϕt
2 2
(1 + 2mG ) sin2 ϕt
Largest gear teeth number
Z2P sin2 ϕt − 4k2 cos2 ψ

ZG =
4k cos ψ − 2NP sin2 ϕt
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Ratna Kumar (IIT Madras) Fundamentals of Gears
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Fundamentals Tooth Systems
AGMA Tooth Systems I
A tooth system specifies the relationships involving addendum,

dedendum, working depth, tooth thickness and pressure angle.
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Standard Tooth Systems for Spur Gears
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AGMA Tooth Systems II
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General Tooth Sizes
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AGMA Tooth Systems III
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Tooth proportions for Helical Gears
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AGMA Tooth Systems IV

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Tooth proportions for 20◦ Straight Bevel Gears
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AGMA Tooth Systems V
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Pressure Angles and Tooth Depth for Worm Gears
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Fundamentals Gear Trains
Gear Trains I
Consider a pinion A driving gear B. The speed of the driven gear

is
ZA dA
NB = NA = NA .
ZB dB
Here,
Z: Number of teeth
N: Speed in rev/min
d: Pitch diameter
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Gear Trains II
Z4 Z5
Z6
Z2
Z3
Speed of gear 6 is
Z2 Z3 Z5
N6 = − N2
Z3 Z4 Z6
Drivers: 2, 3 and 5
Driven: 3, 4 and 6
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Gear Trains III
Train Value
product of driving tooth numbers
Train value e = product of driven tooth numbers
If the last gear rotates in the same sense as first, then e is
positive, else it is negative
NL = eNF
A train value of up to 10 to 1 is possible with one pair

Two-stage compound gear train: train value of 100 to 1 is
possible
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Gear Trains IV
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Two Stage Gear Train
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Gear Trains V
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Guidelines for gear train selection
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Determine the number of teeth (integers) and then their pitch
Determine number of stages necessary to obtain the overall ratio
Keep the portions as evenly as possible between the stages
For e.g., in a two stage gear train, assign the square root of the
overall train to each stage.
Assign the smallest gears to the minimum number of teeth allowed
for the specific ratio
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Gear Trains VI
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Example
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A gear box is needed to provide a 30:1 (± 1 percent) increase in speed,
while minimizing the overall gearbox size. Specify the appropriate
teeth
. numbers.
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Gear Trains VII
Solution
The ratio is greater than 10:1, but less than 100:1, a
two-stage gear box
√
Portion to be accomplished in each stage: 30 = 5.4772
Assume a pressure angle ϕ = 20◦
Minimum number of teeth to avoid interference 16
√
Number of teeth for mating gears is 16 30 = 87.64 = 88
The overall train value is
e = (88/16)(88/16) = 30.25
The above value is within 1% tolerance.

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Gear Trains VIII
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Example 2
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A gearbox is needed to provide an exact 30:1 increase in speed, while
.minimizing the overall gearbox size. Specify appropriate teeth numbers.
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Gear Trains IX
Solution
To obtain integers, factor the overall ratio into integer stages
e = 30 = (6)(5), Z2 /Z3 = 6, and Z4 /Z5 = 5
2 equations and 4 unknown number of teeth; hence two free

choices
Choose Z3 and Z5 to be as small as possible without
interference, i.e., 16
Therefore,
Z2 = 6Z3 = 6(16) = 96
Z4 = 5Z5 = 5(16) = 80
The overall train value is e = (96/16)(80/16) = 30.
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Two-Stage Compound Reverted Gear Train I
d2 /2 + d3 /2 = d4 /2 + d5 /2
We have diametral pitch P = Z/d and assuming same P in both stages
Z2 /(2P) + Z3 /(2P) = Z4 /(2P) + Z5 /(2P)
Z2 + Z3 = Z4 + Z5 J
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Two-Stage Compound Reverted Gear Train II
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Example - 3
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A gearbox is need to provide an exact 30:1 increase in speed, while
minimizing the overall gearbox size. The input and output shafts
should
. be in-line. Specify appropriate teeth numbers.
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Two-Stage Compound Reverted Gear Train III

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Solution
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Governing equations:
Z2 /Z3 = 6
Z4 /Z5 = 5
Z2 + Z3 = Z4 + Z5
Of the two small gears, assume Z3 = 16 and hence
Z2 = 6Z3 = 6(16) = 96
Z2 + Z3 = 96 + 16 = 112 = Z4 + Z5 = 5Z5 + Z5 = 6Z5
Z5 = 112/6 = 18.67
.But we need an exact solution and hence Z5 can’t be rounded.

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Two-Stage Compound Reverted Gear Train IV

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Solution Contd..
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Choice 1: Choose a different Z3 until the solution is obtained
Else, normalize the process
Choose Z3 = 1
Z2 = 6Z3 = 6(1) = 6
Z2 + Z3 = 6 + 1 = 7 = Z4 + Z5 = 6Z5
Z5 = 7/6
The above fraction can be eliminated if it is multiplied by a

multiple of 6.
Hence, the free choice for Z3 should be selected as a multiple of 6.
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Two-Stage Compound Reverted Gear Train V
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Solution Contd..
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Choose Z3 = 18
Z2 = 6Z3 = 6(18) = 108

Z2 + Z3 = 108 + 18 = 126 = Z4 + Z5 = 5Z5 + Z5 = 6Z5
Z5 = 126/6 = 21
Z4 = 5Z5 = 5(21) = 105
Check e = (108/18)(105/21) = 6(5) = 30.

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Planetary Gear Trains I

Some of the gears axes
rotate about other gears
Planetary, epicyclic
Planetary gears always
include a sun gear, a planet
carrier or arm and one or
more planet gears
Planetary gear trains have
two dof
Hence, for constrained
motion, two inputs are
needed
Two inputs: Sun gear (20
rpm, CCW); Ring gear (10
rpm CW) . . . . . . . . . . . . . . . . . . . .
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Planetary Gear Trains II

Sun gear and two planet
gears connected by an arm
Angular velocity of gear 2
w.r.t arm 3
N23 = N2 − N3
Gear 5 relative to Arm 3
N53 = N5 − N3
Therefore,
N53 N5 − N3
=
N23 N2 − N3
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Planetary Gear Trains III
In the ratio of gear 5 to that of 2 N53 /N23 , both the velocities are
taken relative to arm 3. Hence, this ratio is similar to teeth ratio
irrespective of the rotation of the arm.
Hence, train value is given by
N5 − N3
e=
N2 − N3
In other words,
NL − NA
e=
NF − NA
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Planetary Gear Trains IV

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Example-4
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In the planetary gear system

shown in figure, sun gear is the
input. It is driven clockwise at
100 rpm. The ring gear is held
stationary by being fastened to
the frame. Find the rev/min and
direction of rotation of arm and
gear 4.
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Planetary Gear Trains V
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Solution
.
NF = N2 = −100 rev/mini, NL = N5 = 0.
Imagine: Unlock gear 5 and hold the arm stationary
( )( )
20 30 0 − NA
e=− = −0.25 = =⇒ NA = −20 rev/min.
30 80 (−100) − NA
N43 = N4 − N3 , N23 = N2 − N3
N43 20 N4 − (−20) 1
=− = =⇒ N4 = 33 rev/min.
. N23 30 (−100) − (−20) 3
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Force Analysis
Force Analysis
.
Notations to be used
.
Numeral 1 for the frame
2,3,4,. . . for gears
lower case alphabets a, b, c, etc. for shafts
F23 : Force exerted by the gear 2 against gear 3
F2a : Force of gear 2 against shaft a
Ft23 : Tangential force of gear 2 against gear 3
Fr23 : Radial force of gear 2 against gear 3
.
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Force Analysis Spur Gears
Spur Gears I
The forces at the gear contact act along the pressure line
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Spur Gears II
The tangential force is responsible for power transmission

Torque transmitted is given by T = Wt (d/2)
In the above equation, Wt may be replaced by Ft32 , d may be
replaced by d2 and T may be replaced by Ta2
The power transmitted may be written as H = Tω = Wt (d/2)ω
The power transmitted is usually designated in hp or kW
H
Wt = 33000 ,
V
.
where Wt is in lbf, H is in hp and V = πdN/12 in ft/min wherein
d is in inches and N is rev/min.
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Spur Gears III
The corresponding expression in SI units is given by
H
Wt = 60000 ,
πdN
.
where Wt is in kN, H is in kW, d is in mm and N is in rev/min.
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Spur Gears IV
.
Problem
.
Pinion 2 in the below figure runs at 1750 rev/min and transmits 2.5
kW to idler gear 3. The teeth are cut on the 20◦ full-depth system and
have a module of m = 2.5 mm. Draw a free-body diagram of gear 3
and show all the forces that act upon it.
.
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Spur Gears V
.
Solution
.
The pitch diameters of 2 and 3
d2 = Z2 m = 20(2.5) = 50 mm, d3 = Z3 m = 50(2.5) = 125 mm.
The transmitted load is

H 2.5
Wt = 60000 = 60000 = 0.546kN
πd2 N2 π(50)(1750)
Hence, the tangential force of gear 2 on gear 3 is Ft23 = 0.546 kN.

Hence, the radial force is given by Fr23 = Ft23 tan 20◦ = 0.199 kN.
. F23 = Ft23 / cos 20◦ = 0.546/ cos 20◦ = 0.581 kN.
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Spur Gears VI
Note that gear 3 is an idler and it doesn’t transmit any power to
its shaft.
Hence, the tangential reaction of gear 4 on gear 3 is also equal to
Wt . Hence,
Ft43 = 0.546 kN, Fr43 = 0.199 kN and F43 = 0.581 kN.
Equilibrium in x− direction,
Fxb3 + Fr43 − Ft23 = 0 =⇒ Fxb3 = 0.546 − 0.199 = 0.347 kN.
Equilibrium in y− direction
y
Fb3 = Ft43 − Fr23 = 0.546 − 0.199 = 0.347 kN
The resultant force acting on the shaft is

√
Fb = 0.3472 + 0.3472 = 0.491 kN.
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Force Analysis Helical Gears
Helical Gears
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Ratna Kumar Annabattula

208, Machine Design section

Oﬃce hours: Wednesday, 3:00 p.m. - 4:00 p.m.

Spur gears have teeth parallel

(b) Helical Gears

Bevel gears: Teeth formed on

(c) Bevel Gears

Types of Gears III

Transmit rotary motion

(d) Worm Gears

Nomenclature of Spur Gear I

Nomenclature of Spur Gear II

Pitch circle is an imaginary circle

Nomenclature of Spur Gear III

Addendum, a: radial distance between the top land (addendum

Nomenclature of Spur Gear IV

Involute Properties III

Involute Properties VII

Involute Properties VIII

(d′P + d′G )/2 = 14.25 in

Due to conjugate action, the velocity ratio doesn’t change and

d′P /d′G = 8/20

Solving, the above two equations, we get

d′P = 8.143 in, d′G = 20.357 in.

We have rb = r cos ϕ and hence for the pinion,

Arc of action qt = Arc of approach qa + Arc of recess qr

Ratna Kumar (IIT Madras) Fundamentals of Gears July-Nov 2017 24 / 67

Contact Ratio III

Contact ratio is also equal to the length of path of contact divided

Interference in a gear pair

Contact of non-conjugate tooth pairs is called interference.

Let ZP : smallest number of teeth on a spur pinion and gear

where k = 1 for full-depth teeth and k = 0.8 for stub teeth.

Thus, 13 teeth on pinion and gear are interference-free.

The largest gear for a speciﬁed pinion without interference is

Z2P sin2 ϕ − 4k2

For a 13-tooth pinion with a pressure angle ϕ = 20◦ ,

132 sin2 20◦ − 4(1)2

Interference can be reduced by increasing the pressure angle

Forming of Gear Teeth

Self Study 13.8 from Shigley’s book

Bevel Gears Terminology

where p, the circular pitch is

Helical Gears III

For a given gear ratio m = NG /NP , the smallest pinion

Largest gear teeth number

Z2P sin2 ϕt − 4k2 cos2 ψ

AGMA Tooth Systems I

A tooth system speciﬁes the relationships involving addendum,

AGMA Tooth Systems II

AGMA Tooth Systems III

AGMA Tooth Systems IV

AGMA Tooth Systems V

Consider a pinion A driving gear B. The speed of the driven gear

Gear Trains III

A train value of up to 10 to 1 is possible with one pair

Gear Trains VII

The above value is within 1% tolerance.

Gear Trains VIII

e = 30 = (6)(5), Z2 /Z3 = 6, and Z4 /Z5 = 5

2 equations and 4 unknown number of teeth; hence two free

Two-Stage Compound Reverted Gear Train I