Gears NBH Final
Gears NBH Final
Gears NBH Final
1
Gears
Introduction- Gear can be defined as the mechanical element used for transmitting power and rotary motion from
one shaft to another by means of progressive engagement of projections called teeth. Smaller of the pair is called
PINION and the larger of the pair is called the GEAR.
Sr. No. Gear Drive Reduction Ratio Sr. No. Gear Drive Efficiency
1 Single Stage Spur / Helical Gear 6:1 1 Spur / Helical Gear 96-99%
2 Two Stage Spur / Helical Gear 35:1 2 Bevel Gear Drive 95-98%
3 Three Stage Spur / Helical Gear 200:1 3 Worm and Worm Wheel 45-97%
4 Bevel Gear Drive 6:1
5 Single Stage Worm Gear 70:1
6 Double Stage Worm Gear 4900:1
Terminology in Spur Gears
Law of Gearing
The common normal at the point of contact between a pair of teeth must always
pass through the pitch point it is known as Law of gearing Law of Gearing
Let the two teeth come in contact at point Q, and the wheels rotate in the
directions as shown in the figure.
Let TT be the common tangent and MN be the common normal to the curves
at the point of contact Q.
A little consideration will show that the point Q moves in the direction of QC,
when considered as a point on wheel 1, and in the direction of QD when
considered as a point on wheel 2.
Let V1 and V2 be the velocities of point Q on wheels 1 and 2 respectively. If
the teeth are to remain in contact, the components of these velocities with the
normal MN must be equal.
V1 Cosα = V2 Cosβ Where,
(ω1 × O1Q ) Cosα = ( ω2 × O2Q )Cosβ • ω1 & ω2 = Angular velocity of gear
(ω1 × O1Q )×O1M/O1Q =( ω2 × O2Q) × O2N/O2Q 1 & 2.
ω1 × O1M = ω2 × O2N ω1 / ω2 = O2N/O1M • D1 & D2 = Pitch circle diameter of
gear 1 & 2.
Also from similar triangles, O1MP and O2NP • T1 & T2 = Teeth of gear 1.
O2N/O1M = O2P/O1P • O1P & O2P = Distance of P from
So, ω1 / ω2 = O2N/O1M = O2P/O1P = D2/D1 = T2/T1 the centres O1 and O2.
Nomenclature of Spur Gears
Pitch circle- It is an imaginary circle on gear which by pure rolling action would produce the same motion as
the actual gear.
Pressure Angle- ( Ø) Angle between the common normal to the two meshing teeth at the point of contact and
common tangent to the two pitch circles at the pitch point
Pitch Circle Dia.(d)- or PCD- It is the dia. of pitch circle.
Pitch Point – it is a common point of contact between two pitch circles.
Circular pitch- It is the dist. measured along the circumference of the pitch circle, from the point of one tooth to
the corr. Point on the next tooth. Pc = πd/z, where z = No. of teeth.
d p dg m Z p Zg mZ p 1 G
a
2 2 2
Hunting Tooth:
• In gear pair if gear ratio is an integer number like 1, 3/2, 4/3, same tooth on gear will come in contact with same
tooth on pinion which increases the wear on teeth & reduce the life of teeth.
• In such case extra tooth on the gear is added to spread the wear evenly. This extra tooth is called Hunting tooth.
INTERFERENCE: The
Phenomena when the tip of the
tooth undercut the root on its
mating gear is known as
interference
The minimum number of teeth to avoid interference
• The contact portions of the tooth profile which are not conjugate is called interference.
• Interference is the meshing of two non-conjugate profiles.
2ha
Z min STANDARD SYSTEMS OF GEAR TOOTH
m sin 2 A tooth system is a standard which specifies the pressure angle and
Where the relations for addendum, dedendum, working depth, tooth
ha= Addendum of meshing rack thickness and a fillet radius in terms of module.
m = module in mm
Ø= Pressure angle Objective- To attain interchangeability of gears of all tooth number
but of the same pressure angle and module.
1) 14.5° composite system.
2) 14.5° full depth involute.
3) 20° full depth involute.
4) 22.5° full depth involute.
5) 20° stub tooth involute.
Gear Materials
Desirable properties of gear material-
• Sufficient endurance strength in bending.
• Sufficient surface endurance strength.
• Low coefficient of friction.
• Low and consistent thermal distortion.
TYPES OF GEAR MATERIALS
1. Cast Iron- Large size and complicated 2. Steel 3. Non- Ferrous metals-
shapes • High bending endurance copper, Zink, tin, aluminum,
Advantages: strength. bronze- worm gear.
• Cheap • High surface endurance
• Good damping property strength. 4) Sintered Metals low cost
• Good surface endurance strength but low • Ductile gears
bending endurance strength. • Expensive 5) Non-metals Bakelite,
• Graphite presents in C.I. works as lubricant. • Poor damping property. Nylon
• Easily cast in complicated shapes • Sensitive to thermal • Cheap, easy to manufacture
Disadvantages: distortion during heat • Light weight, tolerate errors
Brittle, low bending strength. treatment. in tooth profile.
• Steel pinion and C.I. gear. • Do not have sufficient
strength.
Force Analysis of Spur Gears
To transmit power from one gear to the other, force is applied by the tooth of the driving gear
on the mating tooth of the driven gear. This force, called as Normal Force (F) acts along the
pressure line and is always normal to the tooth surface. This normal force can be resolved into
two components:
1.Tangential component (Ft)– helps in transmission of torque and determines its magnitude.
2.Radial component (Fr)– tends to push the gears apart, has no contribution in power
transmission.
If torque to be transmitted, T is known, tangential component of force can be calculated as,
T 2Tp 2Tg
Ft d p np d g ng
d 2 dp dg
Where d is pitch circle diameter
60 1000 60 1000
Fn acts along the pressure line and Fn along the common tangent, therefore angle
between Fn and Ft is φ , the pressure angle. Referring to Figure, following relations can be
written:
Fr =Ft tan φ and Fn = Ft/cos φ
• Ft=Tangential force.
• P= Power transmitted, W
• V= Pitch line velocity,m/s
• Tp= torque acting on pinion.
• Tg= torque acting on Gear.
• dp= P.C.D. of pinion.
• dg= P.C.D. of Gear.
• np= pinion speed, rpm.
• ng= Gear speed, rpm.
Gear Tooth Failure
Bending failure or tooth Gear Tooth
breakage - Gear tooth is like a Failure
cantilever and subjected to
repetitive bending stresses.
Tooth breakage happens when Bending Failure
total load exceeds beam or breaking of Wear Failure or surface destruction
strength. Avoided by adjusting tooth
module, face width, providing
fillet radius.
Corrosive Scoring
Abrasive Wear Pitting
Wear
ii. Scoring- (scuffing or galling) Metal to metal contact due to lubrication failure. Excessive frictional heat and
overheating of teeth. Welding and Tearing action. (stick-slip phenomena)
iii. Abrasive Wear-Damage caused by particles like dirt, dust in lubricant. Surface injury caused by particles
trapped between mating teeth. Can be avoided by proper filtration of lubricant, use high viscosity oils,
increasing surface hardness.
iv. Corrosive wear-Due to chemical action by improper lubricant, surrounding atmosphere.
Beam Strength of Spur Gear Tooth
Beam strength of the spur gear tooth is the maximum tangential load the gear tooth can take without tooth
failure.
Lewis Equation for Beam strength of spur Gear tooth
Each tooth is considered as a cantilever beam fixed at the base.
• Radial force Fr- Induces a direct compressive stress of small magnitude and can be neglected.
• Tangential Force Ft- Induces a bending stress which tends to break the tooth.
For the gears to be safe in bending, σb should be less than [σb] or Ft should be less than Sb . If gear and pinion are made of same
material, pinion is the weaker member and design is based on its strength. But if those are made of different materials, it is
evident from the Lewis Equation that the gear or pinion having lesser value of product [σ b] x Y is weaker, as m and b are same
for pinion and gear. Also as the gears are subjected to variable stresses, design is based on the endurance limit and allowable
bending stress can be taken as, [σb] = Se/fos
Permissible Bending Stress
Design of gear tooth – Dynamic Load
Drawbacks of Lewis equation are:
1. The tooth load in practice is not static. It is dynamic and is influenced by pitch line velocity.
2. The whole load is carried by a single tooth is not correct. Normally load is shared by teeth since the contact
ratio is near to 1.5.
3. The greatest force exerted at the tip of the tooth is not true as the load is shared by teeth. It is exerted much
below the tip when single pair contact occurs.
4. The stress concentration effect at the fillet is not considered.
The tooth errors combined with the mass of the pinion and gear result in inertia
forces.
Additional forces arising out of the inertia effects are known as dynamic loads.
Dynamic loads arises due to
inaccuracies in tooth profile.
Errors in tooth profile.
Run out of the gear.
Inertia of the rotating masses.
Deflection of the teeth.
Stiffness of the rotating parts.
Depends upon tooth error and pitch line velocity.
Dynamic Load on Gear Tooth
Dynamic Load or Lewis Dynamic Load (Fd or FLD)
1. The velocity factor is used to make approximate allowance for the effect of dynamic loading. The
dynamic loads are due to the following reasons:
2.Inaccuracies of tooth spacing
2.Irregularities in tooth profiles
3.Deflections of teeth under load
FLD or Fd= Ft × Cv
According to Buckingham, small machining error and deflection of teeth under load cause periods of acceleration, inertia forces,
and impact loads on the teeth similar to variable load superimposed on a steady load. The total maximum instantaneous load on
the teeth or dynamic load is FBD or
FD Ft Fi
0.164Vm cb Ft
FBD Ff
0.164Vm 1.485 cb F
Wear Strength of Spur Gear Tooth
Effective Load on Spur Gear Tooth
Application factor- (Ka)
IS Gear Grades
Estimation of Dynamic Load on Gear Tooth – Load Distribution Factor (Km)
1) Given- m, Zp, Zg, b, ha, hf, np, grade, Sup, Sug, BHN, Ka, Km, F.S.
2) Decide weaker part in bending .
3) Calculate bending strength based on step 1
4) Calculate Wear strength ,Fw= dp.b.Q.K
5) Calculate V (pitch line velocity), Kv (velocity factor)
6) Calculate Feff.= Ka.Km.Ft/ Kv in terms of Ft.
7) If Fb is less than Fw, power rating is based on Beam strength and if it is more than Fw, power
rating is based on wear strength.
8) Equating Fb or Fw with Feff x f.s, calculate Ft.
9) P= Ft x V
Gear Lubrication
Objectives of gear lubrication-
LUBRICANTS USED IN GEARS.
Grease.
1) To reduce the possibility of scoring failure.
Straight mineral oil.
2) to reduce the wear of the teeth.
Motor oil.- SAE
3) to reduce the power loss.
Gear oils.
4) to act as coolant by dissipating heat.
5) to carry away the worn-out particles. MODES OF LUBRICATION
6) to minimise noise, vibration and shock.
7) to prevent corrosion. • Grease lubrication.
• Drip-feed lubrication.
• Splash lubrication.
• Spray or jet lubrication.
Solution
1. The Gear Ratio 2. The Circular Pitch
https://byjus.com/question-answer/a-steel-pinion-has-
module-of-4-mm-pressure-angle-20-circ-and-has-22/
Q5. A steel spur pinion has a module (m) of 1.25 mm, 20 teeth and 200 pressure angle. The pinion rotates at 1200
rpm and transmits power to a 60 teeth gear. The face width (F) is 50 mm, Lewis form factor Y= 0.322 and a dynamic
factor Kv=1.26. The bending stress(σ) induced in a tooth can be calculated by using the Lewis formula given below.
If the maximum bending stress experienced by the pinion is 400MPa. The power transmitted is
Q6. A pair of straight spur gears has to reduce speed from 600rpm to 240rpm. The pinion is made of 40Cr1 steel
and has 18 teeth. The gear is of C45 steel and has 45 teeth. The teeth of the wheels, accurately machined with a
20o involute hob, has 4mm module and 45mm face width.
Determine the kW-rating of the gear pair allowing a service factor of 1.3. Take the basic allowable
stresses for 40Cr1 and C45 steel as 175MPa and 150MPa respectively.
The velocity factor for carefully hobbed gears Cv= 6 / (6+V), Where V= pitch line velocity in m/s
Machine Elements in Mechanical Design – Robert L. Mott, Edward M. Vavrek, Jyhwen Wang, Pearson, NY 10013
Contact Stress Number
FIGURE 9–16 Dynamic factor, Kv (Adapted from AGMA 2001
Standard, Fundamental Rating Factors and Calculation
Methods for Involute Spur and Helical Gear Teeth, with the
permission of the publisher, American Gear Manufacturers
Association, 1001 North Fairfax Street, 5th floor, Alexandria,
VA 22314)