Gear terminology

Pitch surface :The surface of the imaginary rolling cylinder (cone, etc.) that the toothed gear may be considered to replace Pitch circle: A right section of the pitch surface Addendum circle: A circle bounding the ends of the teeth, in a right section of the gear. Root (or dedendum) circle: The circle bounding the spaces between the teeth, in a right section of the gear Addendum: The radial distance between the pitch circle and the addendum circle. dedendum: The radial distance between the pitch circle and the root circle

 Clearance: The difference between the dedendum of one gear and the addendum of the mating gear Face of a tooth: That part of the tooth surface lying outside the pitch surface Flank of a tooth: The part of the tooth surface lying inside the pitch surface. Circular thickness (tooth thickness) : The thickness of the tooth measured on the pitch circle. It is the length of an arc and not the length of a straight line

Law of gearing
The law of gearing states the conditions which must be fulfilled by the gear tooth profiles to maintain a constant angular velocity ratio between two gears. It states that the common normal at the point of contact of the two teeth should always pass through a common pitch point

TYPES OF GEARS
1. According to the position of axes of the shafts. a. Parallel 1.Spur Gear 2.Helical Gear 3.Rack and Pinion b. Intersecting Bevel Gear c. Non-intersecting and Non-parallel worm and worm gears

Factors to be considered for gear selection

Various factors that needs to be considered while selecting the type of gear drive for given application are : 1 The relative position of input and output shaft 2 Speed ratio 3 Efficiency 4 Input speed 5 Power to be transmitted 6 Cost

External and Internal spur Gear

Helical Gear
The teeth on helical gears are cut at an angle to the face of the gear. When two teeth on a helical gear system engage, the contact starts at one end of the tooth and gradually spreads as the gears rotate, until the two teeth are in full engagement. This gradual engagement makes helical gears operate much more smoothly and quietly than spur gears Because of the angle of the teeth on helical gears, they create a thrust load on the gear when they mesh. Devices that use helical gears have bearings that can support this thrust load. One interesting thing about helical gears is that if the angles of the gear teeth are correct, they can be mounted on perpendicular shafts, adjusting the rotation angle by 90 degrees

Helical Gear

Herringbone gears
To avoid axial thrust, two helical gears of opposite hand can be mounted side by side, to cancel resulting thrust forces Herringbone gears are mostly used on heavy machinery.

Rack and pinion

Rack and pinion gears are used to convert rotation (From the pinion) into linear motion (of the rack) A perfect example of this is the steering system on many cars

Bevel gears
Bevel gears are useful when the direction of a shaft's rotation needs to be changed They are usually mounted on shafts that are 90 degrees apart, but can be designed to work at other angles as well The teeth on bevel gears can be straight, spiral or hypoid locomotives, marine applications, automobiles, printing presses, cooling towers, power plants, steel plants, railway track inspection machines, etc.

Straight and Spiral Bevel Gears

Bevel gears
On straight and spiral bevel gears, the shafts must be perpendicular to each other, but they must also be in the same plane. If you were to extend the two shafts past the gears, they would intersect. The hypoid gear, on the other hand, can engage with the axes in different planes.

WORM AND WORM GEAR

Worm gears are used when large gear reductions are needed. It is common for worm gears to have reductions of 20:1, and even up to 300:1 or greater Many worm gears have an interesting property that no other gear set has: the worm can easily turn the gear, but the gear cannot turn the worm Worm gears are used widely in material handling and transportation machinery, machine tools, automobiles etc

WORM AND WORM GEAR

GEAR TRAINS
A gear train is two or more gear working together by meshing their teeth and turning each other in a system to generate power and speed It reduces speed and increases torque Electric motors are used with the gear systems to reduce the speed and increase the torque

Simple Gear Train

Compound Gear Train

For large velocities, compound arrangement is preferred Two or more gears may rotate about a single axis

Planetary Gear Train

(Epicyclic Gear Train)

Planetary Gear Train

In this train, the blue gear has six times the diameter of the yellow gear The size of the red gear is not important because it is just there to reverse the direction of rotation In this gear system, the yellow gear (the sun) engages all three red gears (the planets) simultaneously All three are attached to a plate (the planet carrier), and they engage the inside of the blue gear (the ring) instead of the outside. Because there are three red gears instead of one, this gear train is extremely rugged

 planetary gear sets is that they can produce different gear ratios depending on which gear you use as the input, which gear you use as the output, and which one you hold still. They have higher gear ratios. They are popular for automatic transmissions in automobiles. They are also used in bicycles for controlling power of pedaling automatically or manually. They are also used for power train between internal combustion engine and an electric motor

Types of gear generation

Gear shaping Gear hobbing Gear cutting

GEAR SHAPING
Gear shaping is a machinery process for generating teeth by a corresponding cutter. Gear shaping has become a convenient operation and one of the most versatile of all gear cutting operations.

Process Characteristics:
This method of gear cutting is based on the principle that any two

gears will mesh if they are of the same pitch, proper helix angle, and proper tooth depth and thickness. By using a gear-shaped corresponding cutter that is rotated (in relation to a blank gear) produces the gear teeth. The cutters are essentially gears that are used to form the teeth. The cutter reciprocates like the cutting tool in a standard shaper but at a rate of 50 to 450 strokes per minute.

 Gear shaping process makes use of a hardened pillion as a cutter, ground with top rake and clearance. In addition to the reciprocating movement of the cutter, both the cutter and blank rotate at the same pitch line velocity. The relative speed of rotation of the cutter and the gear (blank) is the same as the gear to be cut will have with a pinion of same number of teeth as the cutter.

A - Reciprocating Movement B - Gear Rotation C - Cutter Rotation D - Radial In feed

Process Schematic:
The developing process of gear shaping involves a toothed disk cutter which reciprocates in axial rotations. The work piece (or blank gear) rotates on a second shaft (spindle). The work piece is correspondent with the cutter and it gradually feeds into the cutter while rotating. If a two-step process is used, all tooth spaces are partially cut before the finishing The cutters that are rotated are timed with the work piece. This process produces internal gears, external gears, and integral gearpinion arrangements.

 The machine used for gear shaping generally consists of a base, column spindle, and an arbor. The gear cutter is then mounted on the spindle, and the gear blank is mounted on the arbor. The cutter reciprocates up and down while the work piece(gear blank) is gradually fed into the cutter. At the end of each cutting rotation, the spindle is retracted slightly to discourage anymore cutting into the new cut teeth of the gear.

 Gear shaping process makes use of a hardened pillion as a cutter, ground with top rake and clearance. The types of cutters used for gear shaping can be grouped into about four categories: disk, hub, shank, and helical cutters. The cutters are essentially gears that are used to form the teeth.

Cutting of helical gear by shaping

For generating helical gears by shaping, the cutter should be of helical gear type having hand opposite to that of the work piece As the cutter and the work piece run on parallel axes to generate the necessary helicoidally involute shape on the work piece with the axial advancement of the cutter, it should rotate angularly in forward or reverse direction depending on the hand of the helix, and the amount of rotation for the given axial traverse will depend on the lead of helix to be cut. This is achieved by using a helical guide for the cutter spindle. The hand of the helical guide should be the same as that of the cutter and opposite of the work piece helix hand. The other requirement is that the lead of the guide should be equal to the lead of the cutter.

 Hobbing is a machining process for making gears, spines, and sprockets on a hobbing machine, which is a special type of milling machine. The teeth or spines are progressively cut into the work piece by a series of cuts made by a cutting tool called a hob. Compared to other gear forming processes it is relatively inexpensive but still quite accurate, thus it is used for a broad range of parts and quantities. It is the most widely used gear cutting process for creating spur and helical gears

Gear hobbing

The cutter used for hobbing

 Gear hobbing is a multipoint machining process in which gear teeth are progressively generated by a series of cuts with a helical cutting tool (hob). The hob and the work piece revolve constantly as the hob is fed across the face width of the gear blank. Hobbing uses a hobbing machine with two non-parallel spindles one mounted with a blank work piece and the other with the hob. The angle between the hob's spindle and the work piece's spindle varies, depending on the type of product being produced. Ex:- if a spur gear is being produced, then the hob is angled equal to the helix angle of the hob

 The two shafts are rotated at a proportional ratio, which determines the number of teeth on the blank For example: If the gear ratio is 40:1 the hob rotates 40 times to each turn of the blank, which produces 40 teeth in the blank. Note that the previous example only holds true for a single threaded hob; if the hob has multiple threads then the speed ratio must be multiplied by the number of threads on the hob. The hob is then fed up into workpiece until the correct tooth depth is obtained. Finally the hob is fed into the workpiece parallel to the blank's axis of rotation.

Workpiece after hobbing

Schematic presentation of three views of gear hobbing

 Vertical hobbing machine

Horizontal hobbing machine

Solid carburizing
In this process, the parts to be carburized are packed in boxes surrounded by carbonaceous material along with energizer. The boxes are closed type or closed by clay to prevent ingress of air. These boxes are then heated in a furnace at about 900-950oC The carbon from the carbonaceous material combines with oxygen of the energizer to form carbon monoxide. This carbon monoxide decomposed into carbon dioxide and fresh carbon at the surface of the part, and this fresh carbon then diffuses into the steel.

Gear finishing

Gear shaving
It is cold working process accomplished by rolling the gear in contact and under pressure with three hardened burnishing gears.

Phosphate coating:
It is a chemical process, which attacks the treated ferrous surface and leaves a deposit on it of about 0.01mm in thickness. It prevents or retards scuffing, particularly in hypoid gears, apparently by permitting the engaging tooth surfaces to embed more readily under the prevailing boundary lubrication conditions.

Advantages of Gear drives

a) Compact as compare to belt or chain.
b) Transmit higher power and speed as compare to belt or chain. c) Transmit power between shafts which are parallel / nonparallel, intersecting / non-intersecting. d) Used for wide range of speed ratios. e ) Gear drives are positive drives.

Limitations of gear drives

a) Gear drives are costlier than belt or chain drives. b) Require continuous lubrication and precise alignment. c) Can not be used for transmitting power over very long distance.

Presented by
Arun Kumar H.N. Divakar S.M. Greeshma P Rao Jayteertha Shurpali Likith