Design of Spur Gears

Design of Spur Gears

Concept of Friction Wheels
Frictional force  P No slipping,
When P  Frictional force , slipping will occur,
to avoid slipping tooth are provided over the wheel,
known as gear .
Advantages and Disadvantages of Gear Drives
Advantages
1. Exact velocity ratio.
2. Transmit large power.
3. Small centre distances of shafts.
4. High efficiency.
5. Reliable service.
6. Compact layout.
Disadvantages
1. Manufacturing Cost- Costlier ( Special Machines- Hobbing,
milling etc.)
2. Error in gear cutting- Vibration
3. Requirement of lubricating oil for reliable operation
Classification of Gears
1. According to the position of axes of the
shafts
(a) Parallel, (b) Intersecting, and (c) Non-
intersecting and non-parallel.
herringbone gears.
2. According to the peripheral 3. According to the type
velocity of the gears. of gearing
(a)Low velocity- less than 3 m/s (a) External gearing,
(b) Medium velocity-3 to 15 m / (b) Internal gearing, and
s (c) Rack and pinion
(c)High velocity- more than 15
m/s
4. According to the position
of teeth on the gear
surface.
(a)Straight,
(b)Inclined, and
(c)Curved.
Rack & Pinion

Terms used in Gears
• Circular pitch, p = π d/z equation 12.2 , P.No.162
• Diametral pitch P =z/ d equation 12.2 , P.No.162
• Module m = d/ z , equation 12.4 , P.No.162
1. Pitch circle: imaginary circle that gives same motion similar to actual gear
2. Pitch circle diameter: diameter of the pitch circle
3. Pitch point: common point of contact between two pitch circles
4. Pitch surface: surface of the rolling discs
5. Pressure angle or angle of obliquity: angle between the common normal to two gear
teeth at the point of contact and the common tangent at the pitch point 14 ½ ° and 20°.
6. Addendum: radial distance of a tooth from the pitch circle to the top of the tooth
7. Dedendum: radial distance of a tooth from the pitch circle to the bottom of the tooth.
8. Addendum circle: circle drawn through the top of the teeth
9. Dedendum circle :circle drawn through the bottom of the teeth
Root circle diameter = Pitch circle diameter × cos α, where α is the pressure angle.
10. Circular pitch
11. Diametral pitch
12. Module: T12.2 P.No. 182,DDHB
13. Clearance: radial distance from the top of the tooth to the bottom of the tooth in
meshing of gears
14. Total depth:distance between the addendum and the dedendum circle
15. Working depth: radial distance from the addendum circle to the clearance circle
16. Tooth thickness:width of the tooth measured along the pitch circle
17. Tooth space:width of space between the two adjacent teeth measured along the
pitch circle.
18. Backlash: difference between tooth space and the tooth thickness
Arc of contact. It is the path traced by a point on the pitch
circle from the beginning to the end of engagement of a
given pair of teeth. The arc of contact consists of two parts,
i.e.
(a) Arc of approach. It is the portion of the path of contact
from the beginning of the engagement to the pitch point.
(b) Arc of recess. It is the portion of the path of contact from
the pitch point to the end of the engagement of a pair of
teeth.
Condition for Constant Velocity Ratio of Gears–Law of Gearing
The common normal to the tooth profile at point of contact should always pass
Through a fixed point called the pitch point, in order to obtain a constant velocity
Ratio.
Forms of Teeth
1.Cycloidal teeth
2. Involute teeth
Systems of Gear Teeth
1 . 4 ½ °Composite system,
2. 14 ½ °Full depth involute system,
3. 20° Full depth involute system, and
4. 20° Sub involute system.
T-12.1, 12.4 P.No. 182/183 DDHB
Interference
Minimum Number of Teeth on the Pinion in Order to Avoid Interference
Equation 12.10, P.No.162
Equation 12.11, P.No.162
i = Gear ratio or velocity ratio = z2/ z1 = d2 / d1,

α = Pressure angle or angle of obliquity
Design of Spur
Gears
Gear Materials
Table: 12.7 P.No.186,DDHB
Design Considerations for a Gear Drive
1. The power to be transmitted.
2. The speed of the driving gear,
3. The speed of the driven gear or the velocity ratio, and
4. The centre distance.
The following requirements must be met in the design of
a gear drive :
(a)static /Dynamic loading- Sufficient strength of gear
teeth
(b)wear characteristics for satisfactory life
(c) The use of space and material should be economical.
(d) The alignment of the gears and deflections of the
shafts must be
(e) The lubrication of the gears must be satisfactory.
Beam Strength of Gear Teeth – Lewis Equation
Tooth is assumed as cantilever beam that is subjected to moment M = Ft × h
Ft = 1000 P Cs/ v………… 12.20 a ,P.No. 164,DDHB
Take Cs from T12.8, P.No. 187, as per load on tooth
Ft = Tangential load acting at the tooth,
h= height of the tooth,
Half the thickness of the tooth (t) at critical section BC = t/2,
I = Moment of inertia about the centre line of the tooth = b.t3/12,
b = Width of gear face.
From bending equation σ / Distance of outer(or inner surface from NA)= M/I
σ= (Ft × h,.t/2)/(b.t3/12)
or Ft= (σ × b × t2) / 6 h
In this expression, t and h are variables depending upon the size of the tooth
(i.e. the circular pitch) and its profile.
Let t = X × p , and h = k × p ; where X and k are constants.
WT= (σ × b × X2 pc 2) /( 6 k pc) = (σ × b × y× pc)………12.15,P.No. 163,DDHB
where y= x2/ 6 k or y= t2/ (6 π h m)= Lewis form factor (T-12.5, P.No. 184)
Also form factor Y= π y
The value of y in terms of the number of teeth may be expressed as follows :
y =0.684 - 0.124/ z ………………. ….. for 14 ½ composite and full depth involute
system.
y =0.0.154 - 0.912/ z ……………………..for 20 full depth involute system
y =0.0.175 - 0.841/ z ……………………..for 20 sub involute system
Equation 12.17 a to 12.17 c , P.No. 163 DDHB
σ = σd × Cv
where σd = Allowable static stress, and (T-12.7,P.No. 186)
Cv = Velocity factor ( also see T-12.9 ,P.No. 188)
Cv =3.05/ (3.05 + v) for ordinary cut gears , velocities upto 8 m / s.
=4.58/(4.58 + v) for carefully cut gears operating at velocities upto 13 m/s.
=6.1/(6.1 + v) for very accurately cut and ground metallic gears operating
at velocities upto 20 m/ s.
=0.75/(0.75 + √v) for precision gears cut with high accuracy and operating at
velocities upto 20 m/s,
Equation 12.19a to 12.19 e, P.No. 164 DDHB
Dynamic Tooth Load
Dynamic loads are due to following reasons-
1. Inaccuracies of tooth spacing
2. Inaccuracies in tooth profiles
3. Deflection of tooth under loads
Dynamic load may be obtained as –
Fd= Ft+ Fi
where Fd = total dynamic load,
Ft = Static load due to transmitted torque, and
Fi = Increment load due to dynamic action.
The increment load depend upon the pitch line velocity v, , face width,
b material of gears, the accuracy of cut and tangential load.
For average conditions, dynamic load is determined by using the
following Buckingham equation as-
C may also be obtained from the T-12.12, P.
N0.190 as per error e
error e depending upon pitch line velocity
may be taken from T-12.14,P.No. 191, also
diagram 12.4, p.no. 205
T12.13, P.No. 191, DDHB
Endurance Strength of tooth may be obtained by putting value of σen in Lewis formula
Fen = σen.b.pc.y = σen.b.π m.y equation 12.34 ,P.No.190
σen may be obtained from T 12.15, p.no. 192
Buckingham suggests the following relationship between F en and Fd.
For steady loads, Fen ≥ 1.25 FD
For pulsating loads, Fen ≥ 1.35 FD
For shock loads, Fen ≥ 1.5 FD
Note :
σen = 1.75 × B.H.N. (in MPa) ( This is empirical formula taken from book)
See T 12.15, P.No. 192

Wear Tooth Load
Fw = d1b.Q.K
where Fw = Maximum or limiting load for wear in newtons,
d1 = Pitch circle diameter of the pinion in mm,
b = Face width of the pinion in mm,
Q = Ratio factor
=(2×V.R)/(1+V.R.)=(2 Tg)/(Tg+Tp)…for external gears
= (2×V.R)/(V.R.-1)=(2 Tg)/(Tg-Tp) for internal gears.
V.R. = Velocity ratio = TG / TP,
According to Buckingham, the load stress factor K is given by the following relation :
σes may be taken from T-12.16, P.No. 193

where σes = Surface endurance limit in MPa or N/mm2,
α = Pressure angle,
EP = Young's modulus for the material of the pinion in N/mm2, and
Eg = Young's modulus for the material of the gear in N/mm2.
σes may be taken from T-12.16, P.No. 193
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Design of Spur Gears

Design of Spur Gears

Rack & Pinion

Equation 12.10, P.No.162

Equation 12.11, P.No.162

i = Gear ratio or velocity ratio = z2/ z1 = d2 / d1,

See T 12.15, P.No. 192

σes may be taken from T-12.16, P.No. 193

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