International Conference on Engineering Graphics and Design - Bucharest,Romania 2005

GEARS DESIGN FOR THE MECHANISMS HIGHEST EFFICIENCY

Relly PETRESCU, Florian PETRESCU Abstract: The paper presents an original method to determine the efficiency of the gear. The originality of this method relies on the eliminated friction modulus. The paper is analyzing the influence of a few parameters concerning gear efficiency. These parameters are: z1 - the number of teeth for the primary wheel of gear; z2 - the number of teeth of the secondary wheel of gear; 0 - the normal pressure angle on the divided circle; - the inclination angle. With the relations presented in this paper, one can synthesize the gears mechanisms. Key Words: efficiency, gear, constructive parameters, teeth, outside circle, wheel. 1. INTRODUCTION In this paper the authors present an original method for calculating the efficiency of the gear. The originality consists in the way of determination of the gears efficiency, because one hasnt used the friction forces of couple (this new way eliminates the classical method). One eliminates the necessity of determining the friction coefficients by different experimental methods as well. The efficiency determinates by the new method is the same like the classical efficiency, namely the mechanical efficiency of the gear. The considerate model is very simple. It can be followed in figure 1. 2. DETERMINING THE MOMENTARY MECHANICAL EFFICIENCY The calculating relations [1,2], are the next (see the fig. 1):
F = Fm cos 1 F = Fm sin 1 v = v cos 2 1 1 v12 = v1 sin 1 F = F + F m v1 = v2 + v12

profile 1 to the profile 2) will be written:

n v2 F Fm v1 F v12 t O1 0 1 1 n 1 P rp1 1 rb1 K1 2 2002 Victoria PETRESCU t

Fig. 1. The forces of the gear

Pu P = F v 2 = Fm v1 cos 2 1

(3)

The lost power will be written:

P = F v12 = Fm v1 sin 2 1

(4)

(1) The momentary efficiency of couple will be calculated directly with the next relation:
Pu P F v cos 2 1 = m 1 i = Pc Pm Fm v1 2 i = cos 1

with: Fm - the motive force (the driving force); F - the transmitted force (the useful force); F - the slide force (the lost force); v1 - the speed of element 1, or the speed of wheel 1 (the driving wheel); v2 - the speed of element 2, or the speed of wheel 2 (the driven wheel); v12 - the relative speed of the wheel 1 in relation with the wheel 2 (this is a sliding speed). The consumed power (in this case the driving power):
Pc Pm = Fm v1

(5)

The momentary losing coefficient [3], will be written:

P F v sin 2 1 = m 1 = sin 2 1 i = Pm Fm v1 2 2 i + i = cos 1 + sin 1 = 1

(6)

(2)

The useful power (the transmitted power from the

One can easily see that the sum of the momentary efficiency and the momentary losing coefficient is 1: Now one can determine the geometrical elements of gear. These elements will be used in determining the couple efficiency, .

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3. THE GEOMETRICAL ELEMENTS OF THE GEAR One can determine the next geometrical elements of the external gear, [1,2], (for the right teeth, =0): The radius of the basic circle of wheel 1 (of the driving wheel), (7):
rb1 = 1 m z1 cos 0 2

uses the relations (14, 15 and 16):

tg t = tg 0 cos

(14)
sin t cos

tg 1m = [( z1 + z 2 )
2 z2

(7)

z cos + 4 2 + 4] 2 cos z1 cos t cos z1 cos t cos = z1 +2 cos

sin 2 t

(15)

The radius of the outside circle of wheel 1 (8):

ra1 = 1 m (m z1 + 2 m) = ( z1 + 2) 2 2

cos 1M

(16)

(8)

One determines now the maximum pressure angle of the gear (9):
cos 1M = rb1 = ra1

For the internal gear with bended teeth (0) one uses the relations (14 with 17, 18-A or 19, 20-B): A. When the driving wheel 1, has external teeth: sin t tg 1m = [( z1 z 2 ) + cos (17) 2 z2 cos 2 sin t z2 4 + 4] cos z1 cos t cos 2
cos 1M z1 cos t cos = z1 +2 cos

1 m z1 cos 0 z cos 0 = 2 = 1 1 z1 + 2 m ( z1 + 2 ) 2

(9)

And now one determines the same parameters for the wheel 2, the radius of basic circle (10) and the radius of the outside circle (11) for the wheel 2:
rb 2 = ra 2 1 m z 2 cos 0 2 m = ( z 2 + 2) 2

(18)

(10) (11)

B. When the driving wheel 1, have internal teeth: sin t tg 1M = [( z1 z 2 ) + cos

2 z2

Now one can determine the minimum pressure angle of the external gear (12, 13):
N tg1m = r b1 2 2 N = (rb1 + rb 2 ) tg 0 ra 2 rb 2 = 1 m = m ( z1 + z2 ) sin 0 2 2 2 2 2 ( z2 + 2) z2 cos 0 = m = [( z1 + z2 ) sin 0 2 2 2 z2 sin 0 + 4 z2 + 4 ]

z cos + 4 2 + 4] 2 cos z1 cos t cos z1 cos t cos = z1 2 cos

sin 2 t

(19)

cos 1m

(20)

4. DETERMINING THE EFFICIENCY (12) The efficiency of the gear will be calculated through the integration of momentary efficiency on all sections of gearing movement, namely from the minimum pressure angle to the maximum pressure angle (21), [1, 2]:
=
1
M

tg 1m = [( z1 + z 2 ) sin 0
2 z 2 sin 2 0 + 4 z 2 + 4 ] /( z1 cos 0 )

(13)

am

i d =

cos
m

= =

M 1 1 [ sin( 2 ) + ] = 2 2 m

(21)

Now one can determine, for the external gear, the minimum (13) and the maximum (9) pressure angle for the right teeth. For the external gear with bended teeth (0) one

sin( 2 M ) sin( 2 m ) 1 + ] = [ 2 2 sin( 2 M ) sin( 2 m ) + 0 .5 = 4 ( M m )

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Table 1. Determining the efficiency of the gears right teeth for i12effective= - 4 Table 2. Determining the efficiency of the gears right teeth for i12effective= - 2
0

i12effective= - 4 z1 =8 0 =200 ? m = -16.220 ? M=41.25740 z1 =10 0 =200 ? m = -9.890 ? M=38.45680 z1 =18 0 =190 m = 0.98600 M=31.68300 =0.90105 z1 =30 0 =150 m = 1.50660 M=25.10180 =0.9345 z1 =90 0 =80 ? m =-0.16380 ? M=14.36370

right teeth z2 =32 0 =290 m = 0.71590 M=45.59740 =0.8111 z2 =40 0 =260 m = 1.30770 M=41.49660 =0.8375 z2 =72 0 =200 m =2.73580 M=32.25050 =0.8918 z2 =120 0 =200 m =9.53670 M=28.24140 =0.8882 z2 =360 0 =90 m =1.58380 M=14.93540 =0.9750

0 =35 m = 11.13030 M=49.05600 =0.7308 0 =300 m = 8.22170 M=43.80600 =0.7882 0 =300 m =18.28300 M=38.79220 =0.7660 0 =300 m =23.12250 M=35.71810 =0.7566 0 =200 m =16.49990 M=23.18120 =0.8839

i12effective= - 2 z1 =8 0 =200 ? m=-12.650 ? M=41.25740 z1 =10 0 =200 ? m = -7.130 ? M=38.45680 z1 =18 0 =180 m = 0.67560 M=31.13510 =0.9052 z1 =90 0 =80 m =0.52270 M=14.36370 =0.9785

right teeth z2 =16 0 =280 m = 0.91490 M=45.06060 =0.8141 z2 =20 0 =250 m = 1.33300 M=40.95220 =0.8411 z2 =36 0 =200 m =3.92330 M=32.25050 =0.8874 z2 =180 0 =200 m =16.56670 M=23.18120 =0.8836

0 =350 m =12.29330 M=49.05590 =0.7236 0 =300 m = 9.41060 M=43.80600 =0.7817 0 =300 m =18.69350 M=38.79220 =0.7633 0 =300 m =27.78250 M=32.09170 =0.7507

5. THE CALCULATED EFFICIENCY OF THE GEAR We shall now see four tables with the calculated efficiency depending on the input parameters and once we proceed with the results we will draw some conclusions. The input parameters are: z1 = the number of teeth for the driving wheel 1; z2 = the number of teeth for the driven wheel 2, or the ratio of transmission, i (i12=-z2/z1); 0 = the pressure angle normal on the divided circle; = the bend angle. We begin with the right teeth (the toothed gear), with i=-4, once for z1 we shall take successively different values, rising from 8 teeth. One can see that for 8 teeth of the driving wheel the standard pressure angle, 0=200, is to small to be used (one obtains a minimum pressure angle, m, negative and this fact is not admitted!). In the second table we shall diminish (in module) the value for the ratio of transmission, i, from 4 to 2. One willl see how for a lower value of the number of teeth of the wheel 1, the standard pressure angle (0=200) is to small and it will be necessary to increase it to a minimum value.

For example, if z1=8, the necessary minimum value is 0=290 for an i=-4 (see the table 1) and 0=280 for an i=2 (see the table 2). If z1=10, the necessary minimum pressure angle is 0=260 for i=-4 (see the table 1) and 0=250 for i=-2 (see the table 2). When the number of teeth of the wheel 1 increases, one can decrease the normal pressure angle, 0. One shall see that for z1=90 one can take less for the normal pressure angle (for the pressure angle of reference), 0=80. In the table 3 on increase the module of i, value (for the ratio of transmission), from 2 to 6. In the table 4, the teeth are bended (0). The module i, take now the value 2. 6. CONCLUSION The efficiency (of the gear) increases when the number of teeth for the driving wheel 1, z1, increases too and when the pressure angle, 0, diminishes; z2 or i12 are not that much influenced about the efficiency value; One can easily see that for the value 0=200, the efficiency takes roughly the value 0.89 for any values of the others parameters (this justifies the choice of this value, 0=200, for the standard pressure angle of reference). But the better efficiency may be obtained only for an 0200.

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Table 3. Determining the efficiency of the gears right teeth for i12effective= - 6

Table 4. The determination of the gears parameters in bend teeth for i=-4

i12effective= - 6 z1 =8 0 =200 ? m=-17.860 ? M=41.25740 z1 =10 0 =200 ? m=-11.120 ? M=38.45680 z1 =18 0 =190 m =0.42940 M=31.68300 =0.9028 z1 =30 0 =150 m =1.09220 M=25.10180 =0.9356 z1 =90 0 =90 m =1.36450 M=14.93540 =0.9754

right teeth z2 =48 0 =300 m = 1.77840 M=46.14620 =0.8026 z2 =60 0 =260 m =0.60540 M=41.49660 =0.8403 z2 =108 0 =200 m =2.24490 M=32.25050 =0.8935 z2 =180 0 =200 m =9.34140 M=28.24140 =0.8891 z2 =540 0 =200 m =16.47630 M=23.18120 =0.8841 0 =350 m =10.6600 M=49.05590 =0.7337 0 =300 m = 7.73910 M=43.80600 =0.7908 0 =300 m =18.12800 M=38.79220 =0.7670 0 =300 m =23.06660 M=35.71810 =0.7570 0 =300 m =27.75830 M=32.09170 =0.7509

i12effective= - 4 z1 =8 0 =20
0

bend teeth =15 z2 =32

0

Table 4

0 =300 m = 1.12650 M=46.25920 =0.8046 z2 =72

0 =350 m = 9.44550 M=49.29530 =0.7390 0 =300 m =17.18400 M=39.18030 =0.7702 0 =300 m =22.15500 M=36.25180 =0.7593 0 =300 m =26.94030 M=32.82620 =0.7513

m=-16.8360 ? M=41.08340 z1 =18 0 =19

0

0 =200 m =2.02830 M=32.32020 =0.8938 z2 =120 0 =200 m =8.86020 M=28.45910 =0.8899 z2 =360 0 =200 m =15.89440 M=23.63660 =0.8845

m =0.327150 M=31.71800 =0.9029 z1 =30 0 =15

0

m =1.02690 M=25.13440 =0.9357 z1 =90 0 =9

0

m =1.31870 M=14.96480 =0.9754

But the pressure angle of reference, 0, can be decreased the same time the number of teeth for the driving wheel 1, z1, increases, to increase the gears efficiency; Contrary, when we desire to create a gear with a low z1 (for a less gauge), it will be necessary to increase the 0 value, for maintaining a positive value for m (in this case the gear efficiency will be diminished); When increases, the efficiency, , increases too, but the growth is insignificant. The module of the gear, m, has not any influence on the gears efficiency value. When 0 is diminished one can take a higher normal module, for increasing the addendum of teeth, but the increase of the m at the same time with the increase of the z1 can lead to a greater gauge. The gears efficiency, , is really a function of 0 and z1: =f(0,z1); m and M are just the intermmediate parameters. For a good projection of the gear, its necessary a z1 and a z2 greater than 30-60; but this condition may increase the gauge of mechanism.

7. REFERENCES [1] Petrescu, V., Petrescu, I. Randamentul cuplei superioare de la angrenajele cu roi dinate cu axe fixe. PRASIC 02, Braov, Romania, 2002, Vol. I, p. 333338. [2] Petrescu, R., Petrescu, F. The gear synthesis with the best efficiency. ESFA03, Bucharest, 2003, Vol. 2, p. 63-70. [3] Pelecudi, Chr., .a., Mecanisme. E.D.P., Bucureti, 1985. Authors: Drd. Eng. Florian-Ion PETRESCU, proffesorasisstent, Univ. POLITEHNICA Bucureti, chair TMR, phone: 021. 4029632; Dr. Eng. Relly-Victoria PETRESCU, lecturer, Univ. POLITEHNICA Bucureti, chair GDGI, phone: 0722.529.840.

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