KUMARAGURU COLLEGE OF TECHNOLOGY

P15CCT104 - INTEGRATED MECHANICAL DESIGN

GEARS

Presented By,
RAGHUL S(17MCC006)
 TABLE OF CONTENTS

 Introduction
 General Nomenclature

 Types Of Gears

 Gear Materials

 Gear Tooth Failure

INTRODUCTION:
 A gear is a wheel with teeth that mesh together with
other gears.
 Transmit motion by engaging teeth

 Two or more meshing gears, working in a

sequence, are called a gear train
 Used to change,
 Speed
 Torque

 Direction
GENERAL NOMENCLATURE
Face Width:
 The Face width of a gear is the length of teeth in an
axial plane.
Pressure Angle ( α ):
 Pressure angle is the leaning angle of a gear tooth, an
element determining the tooth profile.
Whole depth:
 The distance from the top of the tooth to the root; it is
equal to addendum plus dedendum or to working depth
plus clearance.
Working depth:
 Depth of engagement of two gears, that is, the sum of
their operating addendums.
Pitch circle:
 A Pitch circle is the curve of intersection of a pitch
surface of revolution and a plane of rotation.
Outside diameter:
 Diameter of the gear, measured from the tops of the
teeth.
Root diameter :
 Diameter of the gear, measured at the base of the tooth.
Clearance:
 Distance between the root circle of a gear and the
addendum circle of its mate.
Addendum:
 Radial distance between the pitch diameter and the
outside diameter.
Addendum circle:
 Coincides with the tops of the teeth of a gear and is
concentric with the standard pitch circle.
Dedendum:
 Radial distance from the depth of the tooth trough to the
pitch surface.
Dedendum Circle:
 The circle touching the bottom of the spaces between
the teeth of a gear wheel.
TYPES OF GEAR:
 Spur Gear
 Helical Gear

 Bevel Gear

 Worm Gear

 Rack And Pinion

 Herringbone Gear
SPUR GEAR:

 Most commonly used Gear type.

 Teeth are parallel to the axis of the gear.

 Transmit power from one shaft to other parallel

shaft.
Advantage:
 Low Cost
 Ease of manufacture

 Availability

Disadvantage:
 Only works with mating gear

 Axis of each gear must be parallel

Applications:
 Washing Machines, Rolling Mills, Marine
Engines.
HELICAL GEAR

 Teeth are at an angle to the gear axis

 This gradual arrangement makes helical gear
operate much more smoothly and quietly than spur
gear
 Can transmit power between Right angle or Parallel
Axis
Advantage:
 Smooth and quiet due to gradual tooth
engagements
 Parallel to perpendicular shaft arrangement

Disadvantage:
 Difficult to Manufacture

 Cost is High

 Resulting axial thrust component

Applications:
 Fertilizer industries, Printing industries, earth
moving industries, Conveyors, Elevators
BEVEL GEAR:

 Usefull when the direction of shaft location has to

be changed.
 Mounted on shaft that are 90deg apart, can also be
designed to work in other angles.
 Teeth can be straight, Spiral or Hypoid
Advantage:
 Operate on Shafts intersecting at an Angle.
 Sliding friction will be low.

Disadvantage:
 Assembled with respective shaft precisely.
 At high speed it will produce noise.

Applications:
 Textile Machine, Sewing Machine.
WORM GEAR:

 Used when large Gear Reduction is needed.

 Have good intersecting property.

 Used widely in material Handling and transportation

machinery, machine tools etc…
Advantage:
 Higher speed reduction could be secured;
speed reduction could be secured up to 300:1
 Worm and worm gears operate silently

Disadvantage:
 Manufacturing cost is high as compared with
manufacturing cost of bevel gear
 Worm and worm gear set will have heavy

power losses.
 Efficiency will be low

Applications:
 Tuning Instruments, Lifts/Elevators.
RACK AND PINION:

 Convert Rotational to Linear motion

 Round Gear – Pinion

Flat or Straight Gear – Rack

 Best example is Car Steering System.
Advantage:
 Rack and pinion gives easier and more
compact control over the vehicle
 Cheap, Compact, Robust.

Disadvantage:
 The rack and pinion can only work with certain
levels of friction.

Applications:
 Rack Elevators, Steering.
HERRINGBONE GEAR:

 Two helical gears that have been placed side by

side.
 Referred to as “double helical”.

 No thrust loading on the bearings

Advantage:
 The double helical form balances the inherent
thrust forces.
 Efficient transfer of torque and smooth motion
at very high rotational velocities.

Disadvantage:
 High cost due to special gear shaping
equipment and special cutting tools.

Applications:
 Used in Heavy Machinery.
GEAR MATERIALS:

 Numerous nonferrous alloys, cast irons, powder-

metallurgy and plastics are used in the manufacture
of gears.
 Steels - commonly used - high strength-to-weight
ratio and low cost.
 Plastics - cost or weight is a concern - Reduce
repair cost.
GEAR TOOTH FAILURE:

 Gear failure can occur in various modes.

 Care has to be taken to avoid such failures

 Types of Gear Tooth Failure:

 Scoring Failure
 Wear Failure

 Pitting Failure

 Plastic Flow

 Tooth Fracture
SCORING FAILURE:

 Occurs Due to Lubrication failure in Contact region

and metal to metal contact.
 Welding and tearing action resulting from metallic
contact removes the metal.
 Types of Scoring:
 Initial Scoring
 Moderate Scoring

 Destructive Scoring
Initial Scoring:
 Occurs by High spots left by previous machine.

 Lubrication failure at this point leads to Scoring

 Scoring stops when temperature, load and speed

remains unchanged.
Moderate Scoring:
 Occurs After initial scoring if the load, speed or oil
temperature increases, the scoring will spread over
to a larger area.
 Progresses at tolerable rate.
Destructive Scoring:
 If the load, speed or oil temperature
increases appreciably, then severe scoring sets in
with heavy metal will occur.
 Predominant over Pitch line since the lubrication
is least at that region.
WEAR FAILURE:

 Wear is a kind of tooth damage where a layers of

metal are removed more or less uniformly from the
surface.
 Tooth Thins and get weakened.

 Cause of gear tooth wear is

 Adhesive Wear
 Abrasive Wear

 Corrosion Wear
Adhesive Wear:
 Hard to detect.

 Occurs from start since the rate of wear is low.

 When the load and speed of operation are more

than mild wear conditions, moderate wear takes
place with higher rate.
 Occurs over long Period.
Abrasive Wear:
 Reason for the failure of open gearing and closed
gearing of machine operated in Abrasive materials.
 Depending on the size, shape and concentration of
the abrasives the wear will change.
Corrosion Wear:
 Due to the chemical action of the lubricating oil or
the additives.
PITTING FAILURE:

 Surface fatigue failure of the gear tooth.

 Occur due to repeated loading of tooth surface and
contact stress.
 Pit is formed.

 Impact load resulting from pitting may cause failure.

 Types of Pitting
 Initial Pitting
 Progressive Pitting
Initial Pitting:
 Small pits of 25 to 50 μm deep are formed just
below the pitch line.
 the load gets distributed over a larger surface area
and stress comes down.
 Common with medium hard Gears.
Progressive Pitting:
 High load and corrective action of initial pitting
leads to Progressive Pitting.
 Pitting begins on the tooth flanks near the line
along the tooth passing through the pitch point.
 Very rare in tooth Face.
PLASTIC FLOW:

 Occurs due to sliding action of Gear.

 Surface deformation Occurs due to yielding of
surface.
 But occurs only in heavy loading Case.
TOOTH FRACTURE:

 Dangerous kind of gear failure leads to disablement

of drive and frequently to damage of other
components.
 Occurs over a long a period of time.

 Tooth failure may result low-cycle fatigue, Repeated

cyclic load
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