CONTENTS CONTENTS CONTENTS CONTENTS

13 428
Theory of Machines
Feaeaeaeaeaturturturturtureseseseses
1. Introduction.

Gear Gear Gear Gear Gear Trainsrainsrainsrainsrains

2. Types of Gear Trains. 3. Simple Gear Train. 4. Compound Gear Train. 5. Design of Spur Gears. 6. Reverted Gear Train. 7. Epicyclic Gear Train. 8. Velocity Ratio of Epicyclic Gear Train. 9. Compound Epicyclic Gear Train (Sun and Planet Wheel). 10. Epicyclic Gear Train With Bevel Gears. 11. Torques in Epicyclic Gear Trains.

13.1.13.1.13.1.13.1.13.1. IntrIntrIntrIntrIntroduction oduction oduction oduction oduction

Sometimes, two or more gears are made to mesh with each other to transmit power from one shaft to another. Such a combination is called gear train or train of toothed wheels. The nature of the train used depends upon the velocity ratio required and the relative position of the axes of shafts. A gear train may consist of spur, bevel or spiral gears.

13.2.13.2.13.2.13.2.13.2. Types ypes ypes ypes ypes of of of of of Gear Gear Gear Gear Gear Trainsrainsrainsrainsrains
Following are the different types of gear trains, de- pending upon the arrangement of wheels : 1. Simple gear train, 2. Compound gear train, 3. Re- verted gear train, and 4. Epicyclic gear train. In the first three types of gear trains, the axes of the shafts over which the gears are mounted are fixed relative to each other. But in case of epicyclic gear trains, the axes of the shafts on which the gears are mounted may move relative to a fixed axis.

13.3.13.3.13.3.13.3.13.3. Simple Simple Simple Simple Simple Gear Gear Gear Gear Gear Trainrainrainrainrain
When there is only one gear on each shaft, as shown in Fig. 13.1, it is known as simple gear train. The gears are represented by their pitch circles. When the distance between the two shafts is small, the two gears 1 and 2 are made to mesh with each other to
428

429
transmit motion from one shaft to the other, as shown in Fig. 13.1 (a). Since the gear 1 drives the gear 2, therefore gear 1 is called the driver and the gear 2 is called the driven or follower. It may be noted that the motion of the driven gear is opposite to the motion of driving gear.
(a) (b) (c) Fig. 13.1. Simple gear train. Let N 1

Chapter 13 : Gear Trains

= Speed of gear 1(or driver) in r.p.m., N
2

= Speed of gear 2 (or driven or follower) in r.p.m., T

1

= Number of teeth on gear 1, and T

2

= Number of teeth on gear 2. Since the speed ratio (or velocity ratio) of gear train is the ratio of the speed of the driver to the speed of the driven or follower and ratio of speeds of any pair of gears in mesh is the inverse of their number of teeth, therefore Speed ratio =N1N2= TT
2

1 It may be noted that ratio of the speed of the driven or follower to the speed of the driver is known as train value of the gear train. Mathematically, Train value = N 2 N 1 = TT
1

2 From above, we see that the train value is the reciprocal of speed ratio. Sometimes, the distance between the two gears is large. The motion from one gear to another, in such a case, may be transmitted by either of the following two methods : 1. By providing the large sized gear, or 2. By providing one or more intermediate gears. A little consideration will show that the former method (i.e. providing large sized gears) is very inconvenient and uneconomical method ; whereas the latter method (i.e. providing one or more intermediate gear) is very convenient and economical. It may be noted that when the number of intermediate gears are odd, the motion of both the gears (i.e. driver and driven or follower) is like as shown in Fig. 13.1 (b). But if the number of intermediate gears are even, the motion of the driven or follower will be in the opposite direction of the driver as shown in Fig. 13.1 (c). Now consider a simple train of gears with one intermediate gear as shown in Fig. 13.1 (b). Let N
1

= Speed of driver in r.p.m., N

= Speed of intermediate gear in r.p.m.,

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Theory of Machines
N
3

= Speed of driven or follower in r.p.m., T

1

= Number of teeth on driver, T

2

= Number of teeth on intermediate gear, and T

3

= Number of teeth on driven or follower. Since the driving gear 1 is in mesh with the intermediate gear 2, therefore speed ratio for these two gears is N1N2= T 2T
1

...(i) Similarly, as the intermediate gear 2 is in mesh with the driven gear 3, therefore speed ratio for these two gears is The speed ratio of the N N2 3 gear = T 3 train T 2 ...(ii) as shown in Fig. 13.1 (b) is obtained by multiplying the equations (i) and (ii).

N1N2T
2T3N2N3T1T2

TN N T i.e. = or 1
=331

Speed ratio = Speed Speed of of driven driver = No. No. of of teeth teeth on on driven driver and

Train value = Speed Speed of of driven driver = No. No. of of teeth teeth on on driven driver Similarly, it can be proved that the above equation holds good even if there are any number of intermediate gears. From above, we see that the speed ratio and the train value, in a simple train of gears, is in- dependent of the size and number of inter- mediate gears. These intermediate gears are called idle gears, as they do not effect the speed ratio or train value of the system. The idle gears are used for the following two pur- poses : 1. To connect gears where a large centre distance is required, and 2. To obtain the desired direction of motion of the driven gear (i.e. clockwise or anticlockwise).

13.4. Compound Gear Train

When there are more than one gear on a shaft, as shown in Fig. 13.2, it is called a compound train of gear. We have seen in Art. 13.3 that the idle gears, in a simple train of gears do not effect the speed ratio of the system. But these gears are useful in bridging over the space between the driver and the driven.
Gear trains inside a mechanical watch

431
But whenever the distance between the driver and the driven or follower has to be bridged over by intermediate gears and at the same time a great ( or much less ) speed ratio is required, then the advantage of intermediate gears is intensified by providing compound gears on intermediate shafts. In this case, each intermediate shaft has two gears rigidly fixed to it so that they may have the same speed. One of these two gears meshes with the driver and the other with the driven or follower attached to the next shaft as shown in Fig.13.2. Fig. 13.2. Compound gear train. In a compound train of gears, as shown in Fig. 13.2, the gear 1 is the driving gear mounted on shaft A, gears 2 and 3 are compound gears which are mounted on shaft B. The gears 4 and 5 are also compound gears which are mounted on shaft C and the gear 6 is the driven gear mounted on shaft D. Let N
1

Chapter 13 : Gear Trains

= Speed of driving gear 1, Since gear 1 is in mesh N T2 ,N
2

,T 3 with 3 ..., ..., N T T gear 1 6 6 = = = Number of teeth on driving gear 1, Speed of respective gears in r.p.m., and Number of teeth on respective gears. 2, therefore its speed ratio is N1N2=TT
12

...(i) Similarly, for gears 3 and 4, speed ratio is N 3 and for gears 5 and 6, speed ratio is N4=TT
4 3

...(ii) N5N6=TT
6 5

...(iii) The speed ratio of compound gear train is obtained by multiplying the equations (i), (ii) and (iii),

N1N2N3N4N5N6=TT21TT4

3TT65

or * N
1N6=

T2T1T4 T6T3 T
5 * Since gears 2 and 3 are mounted shaft C, therefore N 4 =N 5 . on one shaft B, therefore N 2 =N 3 . Similarly gears 4 and 5 are mounted on

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Theory of Machines
i.e. Speed ratio = Speed Speed of the of last the driven first driver or follower = Product Product of of the the number number of of teeth teeth on on the the drivers drivens and Train value = Speed Speed of the of last the driven first driver or follower = Product Product of of the the number number of of teeth teeth on on the the drivens drivers The advantage of a compound train over a simple gear train is that a much larger speed reduction from the first shaft to the last shaft can be obtained with small gears. If a simple gear train is used to give a large speed reduction, the last gear has to be very large. Usually for a speed reduction in excess of 7 to 1, a simple train is not used and a compound train or worm gearing is employed. Note: The gears which mesh must have the same circular pitch or module. Thus gears 1 and 2 must have the same module as they mesh together. Similarly gears 3 and 4, and gears 5 and 6 must have the same module. Example 13.1. The gearing of a machine tool is shown in Fig. 13.3. The motor shaft is connected to gear A and rotates at 975 r.p.m. The gear wheels B, C, D and E are fixed to parallel shafts rotating together. The final gear F is fixed on the output shaft. What is the speed of gear F ? The number of teeth on each gear are as given below : Gear A B C D E F No. of teeth 20 50 25 75 26 65 Solution. Given : N
A Fig. 13.3

= 975 r.p.m. ; T T
A F

= = 65 20 ; T
B

= 50 ; T
C

= 25 ; T
D

= 75 ; T
E

= 26 ; From Fig. 13.3, we see that gears A, C and E are drivers while the gears B, D and F are driven or followers. Let the gear A rotates in clockwise direction. Since the gears B and C are mounted on the same shaft, therefore it is a compound gear and the direction or rotation of both these gears is same (i.e. anticlockwise). Similarly, the gears D and E are mounted on the same shaft, therefore it is also a compound gear and the direction of rotation of both these gears is same (i.e. clockwise). The gear F will rotate in anticlockwise direction. Let N
F

= Speed of gear F, i.e. last driven or follower. We know that Speed Speed of of the the first last driven driver = Product Product of of no. no. of of teeth teeth on on drivens drivers
Battery Car: Even though it is run by batteries, the power transmission, gears, clutches, brakes, etc. remain mechanical in nature. Note : This picture is given as additional information and is not a direct example of the current chapter.

433
or

Chapter 13 : Gear Trains

N A 50 N F = T T A B T D T C T FT
E

= 20 75 25 65 26 = 18.75

NF
=N
A

= = Ans.

13.5. Design of Spur Gears

Sometimes, the spur gears (i.e. driver and driven) are to be designed for the given velocity ratio and distance between the centres of their shafts. Let x = Distance between the centres of two shafts, N
1

975 18.75 18.75 52 r. p. m. = Speed of the driver, T

1

= Number of teeth on the driver, d

1

= Pitch circle diameter of the driver, N

2

,T
2

and d
2

= Corresponding values for the driven or follower, and p

c

= Circular pitch. We know that the distance between the centres of two shafts, x = and speed ratio or velocity ratio,

d1+ d 22 ...(i) N1N2=d2d1=TT

2 1

...(ii) and the From circular the above equations, we can conveniently find out the values of d
1

and d
2

(or T
1

and T
2

) numbers. But in pitch a gear ( p since c ). The the values number of of T 1 its and teeth T 2 , as is obtained above, may or may not be whole always a whole number, therefore a slight alterations be a complete must number. be made in the values of x, d
1

and d
2

, so that the number of teeth in the two gears may Example 13.2. Two parallel shafts, about 600 mm apart are to be connected by spur gears. One shaft is to run at 360 r.p.m. and the other at 120 r.p.m. Design the gears, if the circular pitch is to be 25 mm. Solution. Given : x = 600 mm ; N
1

= 360 r.p.m. ; N
2

= 120 r.p.m. ; p
c

= 25 mm Let We know that speed ratio, d d

1 2

= = Pitch Pitch circle circle diameter diameter of of the the first gear, and second gear. N1N2=d 2d
1

= 120 360 =3 or d
2

= 3d
1

...(i) and centre distance between the shafts (x), 600 = 1 2 (d1+d2 ) or d
1

+d
2

= 1200 ...(ii) From equations (i) and (ii), we find that d

1

= 300 mm, and d

2

= 900 mm Number of teeth on the first gear, T

1

=d 2p
c

= 25

300 = 37.7

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Theory of Machines
and number of teeth on the second gear, T
2

=d 2p
c

= 25 900 = 113.1 Since the number of teeth on both the gears are to be in complete numbers, therefore let us make the number of teeth on the first gear as 38. Therefore for a speed ratio of 3, the number of teeth on the second gear should be 38 3 = 114. Now the exact pitch circle diameter of the first gear, d 1 =T1 p c = 38 25 = 302.36 mm and the exact pitch circle diameter of the second gear, d
2

=T2 p c = 114 25 = 907.1 mm Exact distance between the two shafts, =1+2 =+ =

Hence the number of teeth on the first and second gear must be 38 and 114 and their pitch circle diameters must be 302.36 mm and 907.1 mm respectively. The exact distance between the two shafts must be 604.73 mm. Ans.

13.6. Reverted Gear Train

When the axes of the first gear (i.e. first driver) and the last gear (i.e. last driven or follower) are co-axial, then the gear train is known as reverted gear train as shown in Fig. 13.4. We see that gear 1 (i.e. first driver) drives the gear 2 (i.e. first driven or follower) in the opposite direc- tion. Since the gears 2 and 3 are mounted on the same shaft, therefore they form a compound gear and the gear 3 will rotate in the same direction as that of gear 2. The gear 3 (which is now the second driver) drives the gear 4 (i.e. the last driven or follower) in the same direction as that of gear 1. Thus we see that in a reverted gear train, the motion of the first gear and the last gear is like. Let T
1

x d2d 302.36 2 907.1 604.73 mm = Number of teeth on gear 1,

Fig. 13.4. Reverted gear train.

r
1

= Pitch circle radius of gear 1, and N

1

= Speed of gear 1 in r.p.m. Similarly, T

2

,T
3

,T
4

= Number of teeth on respective gears, r

2

= Pitch circle radii of respective gears, and N

2

,r
3

,r

4,N
3

,N
4

= Speed of respective gears in r.p.m.

435
Since the distance between the centres of the shafts of gears 1 and 2 as well as gears 3 and 4 is same, therefore r
1

Chapter 13 : Gear Trains

+r
2

=r
3

+r
4

...(i) Also, the circular pitch or module of all the gears is assumed to be same, therefore number of teeth on each gear is directly proportional to its circumference or radius.

*T
1

+T
2

=T
3

+T
4

...(ii) and Speed ratio = Product Product of of number number of of teeth teeth on on drivens drivers or N 1 N 4 = TT21 TT
34

... (iii) From equations (i), (ii) and (iii), we can determine the number of teeth on each gear for the given centre distance, speed ratio and module only when the number of teeth on one gear is chosen arbitrarily. The reverted gear trains are used in automotive trans- missions, lathe back gears, industrial speed reducers, and in clocks (where the minute and hour hand shafts are co-axial). Example 13.3. The speed ratio of the reverted gear train, as shown in Fig. 13.5, is to be 12. The module pitch of gears A and B is 3.125 mm and of gears C and D is 2.5 mm. Calculate the suitable numbers of teeth for the gears. No gear is to have less than 24 teeth.

m
A

=m B Solution. = 3.125 mm Given ; m C : = Speed m

D

= 2.5 ratio, mm N
A

/N
D

= 12 ; Let N
A

= Speed of gear A,
Fig. 13.5

T
A

= Number of teeth on gear A, r

A

= Pitch circle radius of gear A, N

B

,N
C

,N
D

= Speed of respective gears, T

B

,T
C

,T
D

= Number of teeth on respective gears, and r

B

,r
C

,r

= Pitch circle radii of respective gears.

* We know that circular pitch, pc =2 T r =m or r = mT .2 , where m is the module. r1 = mT . 12 ; r2 = mT . 22 ; r3 = mT . 32 ; r4 = mT . 4 2 Now from equation (i), mT . 1 2 + mT . 2 2 = mT . 3 2 + mT . 42T 1 +T 2

=T 3 +T 4

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Theory of Machines
Since the speed ratio between the gears A and B and between the gears C and D are to be same, therefore * N
ANB=NCND

= 12 = 3.464 Also the speed ratio of any pair of gears in mesh is the inverse of their number of teeth, therefore TBTA=TT
D C

= ...(i) We know that the distance between the shafts x=r

A

3.464 +r
B

=r
C

+r
D

= 200 mm or m A . T A 2 + m B . T B 2 = m C . T C 2 + m D . T D2 = 200
... 3 r = m. T2

3.125 (T
A

+T
B

) = 2.5 (T
C

+T
D

) = 400 ...( m
A =m B , and m C =m D

) T
A

+T
B

= 400 / 3.125 = 128 ...(ii) and T

C

+T
D

= 400 / 2.5 = 160 ...(iii) From equation (i), T

B

= 3.464 T
A

. Substituting this value of T

B

in equation (ii), T
A

+ 3.464 T
A

= 128 or T
A

= 128 / 4.464 = 28.67 say 28 Ans. and T

= 128 28 = 100 Ans. Again from equation (i), T

D

= 3.464 T
C

. Substituting this value of T

D

in equation (iii), T
C

+ 3.464 T
C

= 160 or T
C

= 160 / 4.464 = 35.84 say 36 Ans. and T

D = 160 36 = 124 Ans. Note : The speed ratio of the reverted gear train with the calculated values of number of teeth on each gear is NAND=TTBAT DT C = 100 28 124 36 = 12.3

13.7. Epicyclic Gear Train

We have already discussed that in an epicyclic gear train, the axes of the shafts, over which the gears are mounted, may move relative to a fixed axis. A simple epicyclic gear train is shown in Fig. gear 13.6, where a gear A and the arm C have B meshes with gear A and has its axis on a the common arm at O axis 2 , about at O 1 which about the which gear they B can rotate. The can rotate. If the
* We know that speed ratio = Speed Speed of of first driver last dri en =NN A D = 12

Also A A CDBD v NN=N NNN ...(N B =N C , being on the same shaft) For N AN B and N CN D to be same, each speed ratio should be 12 so that NAND=N ANBNCND = 12 12 = 12

437
arm is fixed, the gear train is simple and gear A can drive gear B or vice- versa, but if gear A is fixed and the arm is rotated about the upon axis and of around gear A gear (i.e. A. O Such 1 ), then a motion the gear is B called is forced epicyclic to rotate and the gear trains arranged in such a manner that one or more of their members move upon and around another member are known as epicyclic gear trains (epi. means upon and cyclic means around). The epicyclic gear trains may be simple or com- pound. The epicyclic gear trains are useful for transmitting high velocity ratios with gears of moderate size in a compara- tively lesser space. The epicyclic gear trains are used in the back gear of lathe, differential gears of the automobiles, hoists, pulley blocks, wrist watches etc.

13.8. Velocity Ratioz of Epicyclic Gear Train

The following two methods may be used for finding out the velocity ratio of an epicyclic gear train. 1. Tabular method, and 2. Algebraic method. These methods are discussed, in detail, as follows : 1. Tabular method. Consider an epicyclic gear train as shown in Fig. 13.6. Let T
A

= Number of teeth on gear A, and T

B

= Number of teeth on gear B. First of all, let us suppose that the arm is fixed. Therefore the axes of both the gears are also fixed relative to each other. When the gear A makes one revolution anticlockwise, the gear B will make Assuming *T A the / T B anticlockwise revolutions, clockwise. rotation as positive and clockwise as negative, we may say that when gear A makes + 1 revolution, then the gear B will make ( of relative T A /T
B

) motion revolutions. is entered This in statement the first row of the table (see Table 13.1). Secondly, if the gear A makes + x revolutions, then the gear B will make x statement is T entered A /T
B

revolutions. This in the second row of the table. In other words, multiply the each motion (entered in the first row) by x. Thirdly, each element of an epicyclic train is given + y revolutions and entered in the third row. Finally, the motion of each element of the gear train is added up and entered in the fourth row.
* We know that N B /N A =T A

/T B . Since N A = 1 revolution, therefore N B =T A /T B . Fig. 13.6. Epicyclic gear train. Inside view of a car engine. Note : This picture is given as additional information and is not a direct example of the current chapter.

Chapter 13 : Gear Trains