GEAR

SHAH JALPA G
Contents
 Definition
 Classification
 Gear Terminology
 Relations Between Gear Parameter
 Law of Gearing
 Types of gear tooth
 Undercutting
 Gear forming processes
 Gear material
 References
DEFINATION

A Gear is a component within a transmission

device that transmits rotational force to another
gear or device.
 Gear is a round wheel which has teeth that mesh
with other gear teeth, allowing force to be fully
transferred without slippage. Depending on their
construction and arrangement, geared devices
can transmit forces at different speed, torques,
or in a different direction, from the power source.
 The smaller gear in a pair is often called the
pinion; the larger, either the gear, or the wheel.
Mechanical advantage
 Gear
ratio:-
(Speed A * Number of teeth A) = (Speed B *
Number of teeth B)

 Torque ratio & velocity ratio:-

The torque is equal to the circumferential
component of the force times radius. So,
The torque ratio is equal to the ratio of the radii.
This is exactly the inverse of the case with the
velocity ratio. Higher torque implies lower
velocity and vice versa. The fact that the torque
ratio is the inverse of the velocity ratio could also
be inferred from the law of conservation of
energy.
Classification of gear
 Gears can be classified according to the relative positions of their
shaft axes as follows:-
 Parallel shafts :-
 Spur Gear:
Spur gears are the simplest and most
common type of gear. They have
straight teeth parallel to the axes. At
the time of engagement, the contact extends across the
entire width. This results in
sudden application of load, high impact stresses and excessive
noise at high speeds.
 Helical Gears:
In helical gears, the teeth are
curved, each being helical in shape.
At the time of engagement, contact
occurs only at the point of leading
edge of curved teeth. As the gear
rotates contact extends along a diagonal line
across the teeth. This results into low impact stresses
&reduction of noise. So it can be used at
higher velocity & greater load carrying capacity.
They have the disadvantage of having end thrust
So the bearing & the assembly mounting the helical
gear must be able to withstand thrust load.
 Double Helical Gear:
Double helical gears, invented by Andre Citroen
and also known as herringbone gears, overcome
the problem of axial thrust presented by 'single'
helical gears by having teeth that set in a 'V'
shape. Due to its shape axial thrusts of the two
rows of the teeth cancel each other out. These
can be run at high speeds with less noise and
vibrations.
 Intersecting shafts:-
 Straight Bevel Gears:
The teeth are straight, radial to the
point of intersection of the shaft
axes and vary in cross-section
throughout their length. They are
use to connect shafts at right angles which run
at low speeds. They make line contact similar
to spur gear.
 Spiral Bevel Gear:
The tooth elements are curved in shape of a
spiral so that the contact between the inter-
meshing teeth being gradual.
They are smoother in action and quieter than
straight tooth bevels as there is gradual
load application and low impact stresses.
There exist an axial thrust calling for stronger
bearing and supporting assemblies.
 skew shafts:-
 Worm Gear:
A worm is a gear that resembles a
screw. It is a species of helical gear,
but its helix angle is usually
somewhat larger its body is usually
fairly long in the axial direction. Helical gears are, in
practice, limited to gear ratios of 10:1 and under;
worm gear sets commonly have gear ratios between
10:1 and 100:1, and occasionally 500:1.
 Hypoid Gear:
Hypoid Gear resemble spiral bevel gear, except
that the shaft axes are offset, not intersecting..
Hypoid gears are almost always designed to
operate with shafts at 90 degrees. Contact
between hypoid gear teeth may be even
smoother and more gradual than with spiral
bevel gear teeth.
 Pitch &Pitch Circle:
Pitch is a distance between a
point on one tooth and the
corresponding point on an
adjacent tooth.

• Circular pitch is the arc distance along a specified pitch

circle or pitch line between corresponding profiles of
adjacent teeth.
• Diametral Pitch : It is the ratio of the number of teeth to
the pitch diameter. The unit of it is the inverse of inch.
 Tip Circle : This is a circle which bounds the
outer edges of teeth of a gear and its diameter is
denoted by da.
 Root Circle : This is the circle which bounds the
bottoms or the roots of the teeth and its
diameter is denoted by df.
 Base Circle : This is the circle from which the
involute tooth profile is developed. Its diameter
is denoted by db.
 Addendum : It is the radial distance between
the pitch circle and the tip circle and it is denoted
by ha.
 Dedendum : It is the radial distance between
the pitch circle and the root circle, denoted by hf.
 Land : The top land and the bottom land are the
surfaces at the top of the tooth and the bottom
of the tooth space respectively.
 Working Depth : This the distance of
engagement of two mating teeth and is equal to
the sum of the addendums of the mating teeth of
the two gears in the case of standard system.
 Whole Depth : This is the height of a tooth and
is equal to the Addendum plus Dedendum.
 Clearance : This is the radial distance between
the top land of a tooth and the bottom land of
the mating tooth.
 Face Width : This is the width of the gear and is
the distance from one end of the tooth to the
other end.
 Face of Tooth : This is the surface of the tooth
between the pitch cylinder and the outside
cylinder.
 Flank of Tooth : This is the surface of the tooth
between the pitch cylinder and the root cylinder.
 Module : It is defined as the ratio of the pitch
diameter to the number of teeth of a gear. Its
unit is in mm.
 Chordal Addendum :
This is the height bounded by the
top of the tooth and the chord
corresponding to the arc of the
pitch circle representing the
circular tooth thickness.
• Chordal Tooth Thickness : This is the thickness
as shown in above fig.
Relations Between Gear Parameters :
These terms described below are defined in relation to
two gears in mating condition.
Arc of action :
Arc of action is the arc of the pitch circle through which
a tooth profile moves from the beginning to the end of
contact with a mating profile.
 Arc of Approach :
It is the arc of pitch circle
through which the tooth profile
moves from the beginning of
contact until the point of
contact arrives at the pitch pt.
 Arc of recess :
Arc of recess is the arc of the pitch circle through which a
tooth profile moves from contact at the pitch point until
contact ends.
• Line of action :
This is the line along which the
point of contact of the two
mating tooth profiles moves.
This is also known as the path
of contact and is the same as
common tangent.
 Length of action :
Length of action is the
distance on the line of action
through which the point of
contact moves during the
action of the tooth profile.
• Pressure Angle :
If a tangent is drawn to the involute profile of a
tooth at any point on the curve and If a radial
line is drawn through this point of tangency,
connecting this point with the center of the gear,
then the acute angle included between this
tangent and the radial is defined as the pressure
angle at that point.
The Law Of Gearing :
The Law Of Gearing is summarized as follows: "A
 common  normal  to  the  tooth  profiles  at
 their  point  of  contact  must,  in  all  positions
 of  the contacting teeth, pass through a fixed
point on the line-of-centers called the pitch
point." Any two curves or profiles engaging each
other and satisfying the law of gearing are
conjugate curves.
Types of gear tooth :
 Full depth, 200 involute system :
Pressure angle is 200 in these type of tooth, they have stronger
root sections compared to the system having smaller Pressure
angle.
• Full depth, 14½0 involute system :
This was the earliest system used, and preferred because the
sine of 14½0 is ¼.The whole depth is 2.157 times the module
and the working depth is twice the module. In this case
Addendum=1*module and Dedendum=1.157*module.
Number of the teeth of the gear is large enough to avoid
undercutting.
 Full depth,150 involute system :
Here the pressure angle is 150 , this system is much used in
Continental Europe. In both 14½ 0 and 150 systems , the
undercutting begins when the number of gear teeth is below
32.
• Stub tooth system :
This class of the tooth system reduces the interference
problem by having shorter addendum and large pressure
angle, usually 200
In this caseWholedepth=1.8*module
Addendum=0.8*module ,Dedendum=1.0*module
Working depth=1.6*module,
Clearance=0.2*module
Undercutting :
Undercut is a condition in
generated gear teeth when
any part of the fillet curve lies
inside of a line drawn tangent

to the working profile at its

point of juncture with the
fillet. Undercut may be deliberately introduced to
facilitate finishing operations. With undercut the
fillet curve intersects the working profile. Without
undercut the fillet curve and the working profile
have a common tangent.
Gear forming processes :
 Thereare multiple ways in which gear blanks can
be shaped through the cutting and finishing
processes.

 Broaching
 Honing
 Hobbing
 Lapping
 Milling
Gear material :
 Steel : It is most commonly used gear material
Because of their versatility to meet a whole
variety of divergent specifications along with their
easy availability and their ability to combine
greater strength per unit volume coupled with low
cost per kg. The majority of gears are composed
of carbon and low-alloy steels, including carburized
steels. For example gears to be used in food
processing are made of stainless steels or nickel-
base alloys because of their corrosion resistance.
 Cast iron : They are cheap and having good
damping capacity. When gears are to be
complicated shape, cast iron may well be the
only choice in certain cases. This is used where
the strength is not the main criterion. Graphite
present in cast iron part acts as lubricant. When
higher load carrying capacity and resistance to
contact stresses are desire then spheroidal
graphite may be used.
 Non-Ferrous Metals : Various types of bronzes
are used as gear materials, mainly because of
their ability to withstand heavy sliding loads. It is
easy to cast into complicated shapes when
necessary.
 Non-metals : These materials are mainly
selected because of their quietness during
service at high speed, vibration damping ability
and low cast in bulk manufacturing. Materials
used for gear making are generally reinforced
phenolic moulding materials, moulded plastic like
nylon, hard fabrics, raw hide etc.
References :
 Hand book of gear design by Maitra

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