1.1 Spur Gearing Definitions and nomenclature Condition for transmission at constant velocity Velocity of sliding Path and arc of contact Interference Simple and compound trains Torque and power1.1 Spur Gearing Spur teeth are parallel to the axis of the wheel and are usually of involute profile. When two gears are in mesh, the larger is termed the wheel or spur and the smaller the pinion. Quantities relating to the wheel and pinion are normally denoted by capital and small letters respectively. = Pitch cites ] Med I Driver ) 2’ Follower Lino donee y. I HT sats Hf Advantages and Disadvantages of Gear Drives ‘Advantages: = Transmits exact velocities ‘May be used to transmit large power + Has high efficiency + Has reliable service * Compact layout Disadvantages: * Manufacturing require special tools and machinery * The errors during cutting of teeth could cause vibrations and noise Definitions and Nomenclature (Terms used in Gearin evrares celePINION Pitch circle diameter (PCD) or (D,d ) : The diameters of the circle or discs which by pure rolling action would transmit the same motion (velocity ratio) as the actual gear. D=mtg and d=mtp If Torte and t or tp are the numbers of teeth and @ and w are the angular velocities of the wheel and pinion respectively, then, since the circumferential velocity of both pitch circles is the same, 2 _d_t(tp) @ DT The pitch circle radii are denoted by R and r and the pitch point is the point of contact of ‘two pitch circles, =™2 and Pressure angle ( y): The angle between the line of action and the common tangent to the pitch circles at the pitch point OR The angle between the profile of a gear tooth and a radial eat its pitch point, also known as angle of obliquity. ‘Addendum : the radial height of the tooth tip above the pitch circle. The radii of the addendum circle are denoted by R, and ry Maximum addendum = m (nearest standard value), for standards teeth profiles, orfe tp where G = Gear rati Amax = [( s+3¢+2s0e0) Ta max =T[(/1 + GG +2)sin’y)] where G Dedendum: the radial depth of a tooth below the pitch circle, to root of tooth, te = Gear ratio =“ Addendum circle: The circle drawn through the top of the teeth and is concentric with the pitch circle, Dedendum circle: The circle drawn through the bottom of the teeth — also called the root circle. Root circle diameter = PCD x cos, where q is the pressure angle, Circular pitch (p, or p) the distance between a point on one tooth and the corresponding point on an adjacent tooth, measured along the pitch circle circumference, nD _ na ie. Dc = — = = mm (where m= module) te te Gears will mesh correctly if they have the same Circular Pitch - for two gears to mesh comrecty: pe ==" or B= Diametral Pitch (P or P4): the number of teeth on a gear divided by its diameter (PCD), thus the teeth per millimeter of P.C.D. 1 ie Pa ~ since m T ‘Module (m): The pitch circle diameter in millimeters divided by the number of teeth or the Did 1m number of millimeters of P.C.D. per tooth, ie. m=2=S=— Pe at Standard modules are : 0.5 by 0.5t0 6.5, 7by1to16, 18, 20by5to5S0 Clearance: The radial distance from the tip of the tooth to the bottom of the tooth space in the mating gear. Total depth: The radial distance between the addendum and dedendum circles of a gear. Equal to the sum of the addendum and dedendum Working depth : the sum of the addenda of two mating teeth. Gireutar pitch Tooth thickness: is measured along the pitch line (arc) and is equal to ne approximately Tooth space: The width of space between the two adjacent teeth measured along the pitch circle.Backlash: The difference between the tooth space and the tooth thickness, as measured along the pitch circles. Theoretically backlash should be zero, but in practice some backlash must be allowed to prevent jamming — thermal expansion. Profile of teeth: The curve formed by the face and flank of the tooth. Path of contact: The path traced out by the point of contact of two teeth from the beginning to the end of engagement. Length of path of contact: The length of the common normal cut-off by the beginning to the end of engagement. Arc of contact: 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, Le Arc of approach: The portion of the path of contact from the beginning of the engagement to the pitch point. ‘Arc of recess: The portion of the path of contact from the pitch point to the end of the engagement of a pair of teeth. path of contact oy Arc of contact = Arc of approach + Arc of recess The ratio of the length of arc of contact to the circular pitch is known as the contact ratio (n), i.e. the number of pairs of teeth in contact. Length of are of contact The number of pairs of teeth in contact or contact ratio (n| — e.g. fora Contact ratio of 1.5- _the least number of pairs of teeth in contact: 1 the maximum number of pairs of teeth in contact: 2 Path of approach = Arc of approach x cos p Path of recess = Arc of recess x cos Centre distance (C) between two gear wheels on parallel shafts Line of action: The line normal to a pair of mating teeth profiles at their point of contact. Angle of action of the pinion: The angle turned by the pinion when one pair of teeth is in mesh Arcof contact Fitch circle raatas TANS Angle of action = Involute: The path of a point on a straight line which rolls, without slipping, round the circumference of a circle. Base circle : the circle from which the involute curves forming the tooth profiles are drawn. Common tangent: The tangent common to both pitch circles at the pitch point.Common normal: The line normal to the profiles of both teeth at the point of contact, Interference occurs when contact takes place between parts of teeth which are of involute form. For no interference, all points of contact must be within the length of the common tangent to the base circles from which the involutes are generated. inion Torque Power Normal force between teeth = Palen Tortus, where Tp = #988 as P = wT at cosp 5 o = and, Base circle radius, rp For no interference: Ranax2R For no interference on a rack: Rack addendum ¢ r.sin’ y Standard proportions : The proportions recommended by the British Standards Institution in B.S, 436— 1940, for 20° full depth involute system, are : addendum = 1/pe = 1m dedendum = 1.25/p. = 125m working depth = 2pe = 2m minimum total depth = addendum + dedendum =m = 1,25 m= 2,25 m tooth thickness = 1.5708m minimum clearance 25m Condition for Constant Velocity Ratio (Law of Gearin; In the figure shown below, O; and OQ; are the centres of the pinion and wheel respectively, lib is the common normal at the point of contact, C and Os1; and Ol are the perpendiculars from 0; and O, respectively to the common normal. Let uci be the velocity at point C on the pinion and v2 be the velocity of point C on the wheel. If the teeth are to remain in contact, the components of these velocities along the common normal Iyl; must be equal, ie, vacosa = ve cos ie, @ OCeosa=20;CeosB ie, @Oh=QOb @ = Sole OP _D_te + Velocity ratio = 5 = Mt =r =o = To have a constant angular velocity ratio () for all positions of the wheels, the point P must be the fixed point, called pitch point for the two wheels. In other words , the commonnormal at the point of contact between a pair of teeth must always pass through the pitch point. This is a fundamental condition which must be satisfied while designing the teeth Profiles of gears — it is also known as the law of gearing. This condition is fulfilled by the teeth of involute form, provided that the base circles from which the profiles are generated are tangential to the common normal. Since all points of contact lie on the common normal, itis called the line of contact. The force between two mating teeth acts along the line in the absence of friction, so that itis also called the pressure line. Pitch ine speed, v (m/s) = wr = OR Rolling and Sliding The figure below is the general case and depicts a combination of rolling and sliding. Unless the two members are separating or crushing, the normal components, na and ns of points A and B must be equal and lie along the line NN which is the common normal at the instant in question.The actual velocities of A and B are not the same, nor are their directions the same. Their tangent components th and ts must both lie in the direction of the common tangent TT, but they have different magnitudes and may even have opposite sense. The algebraic difference of these tangential components represents the amount of that is taking place. Velocity of Sliding of teeth Refer to the figure under Path of Contact, on next page. The velocity of sliding is the velocity of one tooth relative to its mating tooth along the common tangent at the point of contact. The tangential components of velocities vei and vz at the point C (any point of contact between A and B) are vsina and ve sinB Hence, Velocity of sliding, vs = va sina - va sin = (@ + w) PC The maximum velocity of sliding occurs at the first (A) or last (B) point of contact, depending which is furthest from P (Pitch point) and the velocity of sliding is proportional to the distance from the Picth point (P), thus vs»= 0 mm/s Where: PC = for max velocity of sliding PC would be the furthest point of contact from the pitch point (could be either Path of approach or Path of recess) = Path of Approach or Recess for Vsicingmax(Whichever is the greatest) Sliding velocity at Point of Engagement (A): vsq= (2 + w POA Sliding velocity at Point of Disengagement (B): usa = (2 + w )POR Sliding velocity at Pitch Point (A): vse = 0 mm/s as the velocity of sliding is proportional to the distance from the pitch point (P) Tooth Pressure When power is being transmitted, the maximum tooth pressure (neglecting friction at the teeth) is exerted along the common normal through the pitch point. This force may be resolved into tangential and radial (or normal) components. These components act along and at right angles to the common tangent to the pitch circles. In the figure below, O; and Q; are the centres of the two wheels while MN is the common normal which intersects the line of centres 0,0, at the fixed point, P (pitch point). If Fis the maximum tooth pressure as shown, then Tangential force, Fr = Feos and the radial force, Fy = Fsin “ Torque exerted on the gear shaft = F; x7", where rs the pitch circle radius of the gear Note that the tangential force provides the driving torque and the radial force produces radial deflection and bending of the shafts. é 10Path of Contact (POC) (Length of) ‘Assuming the pinion to be the driver, the first and last points of contact are A and B, as per the figure below, where the addenda circles cut the common normal. The path of contact is ‘AB, which is divided into the path of approach, AP, and the path of recess, BP. Length of Path of Approach (POA) = AP=Al,—Plz =(R,°- R’ cos”) -Rsiny (Path of Contact when engagement occurs) Length of Path of Recess (POR) = PB=BP= Bl - Pl = y(t," ~ r°cos*y) = rsinp (Path of Contact when disengagement occurs) and AB = AP+BP Length of Path of Contact (POC) = Path of Approach (POA) + Path of Recess (POR) unArc of Contact(AQC) (length of) and contact ratio (n! ‘The arc of contact is the arc of the pitch circle EF, refer to the figure above, between the Positions of a tooth at the first and last points of contact with its mating tooth. It is divided into the arc of approach, EP, and the arc of recess, PF. From the construction of the involute curve, arc Mi line AP. ath ofapproach arc of approach (Aa) = Path ofapproach (POA) cos p and, arc of recess (AOR) pre arc of ontact (40) « Patbefeontnt 600 arcofeontact _ AoC Number of pairs of teeth in contact, or contact ratio (n) ar piten circular pitch pe V(R,?- RP cos? y) + y(r,’- 1 cos’ y) - (R+r)siny Contact ratio = cape ‘The maximum and minimum pairs of teeth in contact are the nearest whole number above and below this value ~ e.g. a contact ratio of 1.78 would mean that the minimum pairs of teeth in contact = 1 and the maximum pairs of teeth in contact = 2. Furthermore that 1 pair of teeth will always (100%) be in contact and that for 78% of the time, two pairs of teeth will be in contact. ‘The minimum value for the contact ratio is 1, which means that their must always be at least 1 pair of teeth in contact for continuous action. The larger the contact ratio, the quitter the gears will operate. Angle of Action: The angle turned through by the pinion (or gear) when any one pair of Length of arc of contact th (contact) = ——— SOF of Co x 360° teeth isin mesh (contact) = 7 -imperence of pinion (or gear) © 2Exercise 1.1 A single reduction gear of 120kW with a pinion 250mm PCD and speed 650 rpm is supported in bearings on either sides. Calculate the total load due to the power transmitted, the pressure angle being 20°, ‘Ans. 15.026KN Exercise 1.2 ‘The number of teeth on each of the two equal spur gears in mesh are 40. The teeth have 20" involute profile and the module is 6mm. If the arc of contact is 1.75 times the circular pitch, find the addendum. Ans 6.12mm Exercise 1.3, A pinion having 30 teeth drives a gear having 80 teeth. The profile of the gears is involute with 20° pressure angle, 12mm module and 10mm addendum. Find the length of (a) path of contact, (b) arc of contact and (c) the contact ratio. ‘Ans. 52.3mm , $5.66mm , 1.5 Exercise 1.4 ‘Two involute gears of 20° pressure angle are in mesh. The number of teeth on the pinior 20 and the gear ration is 2. If the pitch expressed in module is Smm and the pitch line speed is 1.2 m/s, assuming addendum as standard and equal to one module, find: (a) The angle turned through by the pinion when one pair of teeth is in mesh (b) The maximum velocity of sliding Ans. 29.45° ; 455.5 m/s Exercise 1.5, ‘A pair of gears having 40 and 20 teeth respectively are rotating in mesh, the speed of the smaller (the driver) being 2000 rpm. If these gear teeth are of 20° involute profile, addendum length is Smm and the module is 5mm, determine the velocity of sliding between the gear teeth at: (a) The point of engagement (b) The pitch point (6) The point of disengagement, and (a) Determine the angle through which the pinion turns while any pair of teeth are in contact Ans. 3975 mm/s ; Omm/s; 3614 mm/s ; 29.45° 13Interference: For correct tooth action the points of contact on two mating teeth must lie on the involute Profiles. If the addendum of one tooth is too large, however, contact may occur between the tip of that tooth and the non-involute portion of the mating tooth between the base circle and the dedendum circle. This causes undercutting of the mating tooth and interference is said to occur. For no interference between the teeth, the first and last points of contact must lie between the points of tangency, I; and I,, ie the addendum circles must cut the common tangent to the base circles between I and Iz, R, = R+addendum ; max Rt addendum max ie Ramox = Y(R? +2Re sin? y +1° sin? y) Ifthe standard addendum, m, is used, then, for no interference 4 _2r mot = 5 s addendums and, addendumnax= Ramer - R= y(R'+2Rrsin® y +1 sin’ y)-R 2 SR iyap so, 7 8 VOR FRR rsin® y +r y)-R (a?s2Gsm?w tom (GP +2Gsin' y +sin"¥)-— where Gis the gear ratio R/r © Tecersin? y Gs20)-0) [(esnry c20-0) Minimum teeth for no interference: 2a¢ 6 & <2 ____, where ag = addendum of Gear ol fisdesaysiney—t Witte Take the next whole value for tg that is dividable by the Gear Ratio (6) 2ap tp ——, where ap = addendum of Pinion Free 2)siny—A te me where te=teeth on rack; ay = addendum of Rack To just avoid interference: Path of Contact = max length of Path of Approach + max Length of Path of Recess = Rsin y+ rsin yp Minimum number of teeth on a 20° involute system pinion, to mesh with any gear (including a rack), without interference = 18 4Rack and pinion Pitch ia ot pinion Rack and pinion is used to convert a rotary motion to translating motion or vice versa (either the pinion drives the rack or the rack drives the pinion). The figures above shows a rack in mesh with a pinion. Rack can be imagined as a spur gear having an infinite diameter. Therefore the rack has an infinite number of teeth and a base circle which is infinite distance from the pitch point. With infinite diameter of base circle, the involute outline of teeth on rack becomes straight lines. The teeth are straight sided and normal to the line of contact. Referring to the figure shown and assuming the pinion to be the driver, Path of approach =AP =a cosec Where a= rack addendum, and Path of recess=PB=BI-PI = y(r,’- 1 cosy) - rsin +: Path of contact, AB = path of approach + path of recess = AP + PB 15For no interference between the rack tips and the pinion flanks, maximum rack addendum = IX = IP sin sity Maximum path of contact = IB y(r," = 1? cos* y) Ifthe standard addendum, 1/P , is used for the rack, then addendum < addendummses ar addendum (m) = < rsin’y Ate 2cosec'p Wyss 1232 iy = 20° ree 16Exercise 1.6 Each of two gears in a mesh has 48 teeth and a module of 8mm. The teeth are of 20° involute profile. The arc of contact is 2.25 times the circular pitch. Determine the addendum ‘Ans. 10.6mm, Exercise 1.7 Two gear wheels of 4.5 module have 24 and 33 teeth respectively. The pressure angle is 20° and each wheel has a standard addendum of 1 module. Find the length of the arc of contact and the maximum sliding velocity ifthe speed of the smaller wheel (driver) is 120 rev / min Ans. 23.16 mm, 242 mm/s Exercise 1.8 ‘Two involute gears in mesh have 20° pressure angle. The gear ratio is 3 and the number of teeth on the pinion is 24. The teeth have a module of 6mm. The pitch line velocity is 1.5m/s and the addendum equal to one module. Determine (a) the angle of action of the pinion and (b) the maximum velocity of sliding. ‘Ans. 25.59" , 445.6mm/s Exercise 1.9 ‘When in mesh, two gear wheels with 95 and 20 teeth of involute form rotate in opposite directions and operate with pressure angle of 20°, a module of 4 mm and a contact ratio of 1,5. The arc of recess is 1,2 times the arc of approach. The smaller wheel runs at 2000 rev/min and transmits 4 kW to the larger wheel. Determine a) The addendums of the two wheels (assume that the teeth are not standard), b) The greatest speed of sliding between a pair of mating teeth, and ©) The greatest force between a pair of mating teeth, if the effects of friction between the teeth are neglected. Ans.2,9mm, 4,24mm, 2,45 m/s, 508N Exercise 1.10 ‘Two 20° gears have a module of amm and the number of teeth on the gear is 40 and the pinion is 24. If the pinion is the driver and rotates at 600 rpm, determine (a) the velocity of sliding when the contact is at the tip of tooth on the pinion. Take the addendum equal to one module. Also find (b) the maximum velocity of sliding, Ans. 950.8mm/s 1017.1mm/s wvExercise 1.11 The following particulars of a single reduction spur gear are given gear ratio = 10 to 1, distance between centers = 660mm, approximately; pinion transmits 500 kW at 1800 rev/min; involute teeth of standard proportions ( addendum = m ) with a pressure angle of 22,5°; permissible normal pressure between teeth = 175 N per mm of width, Find a) The nearest standard module if no interference is to occur, b) The number of teeth in each wheel and radi, c) The necessary width of the pinion, and d) The loads on the bearings of the wheels due to the power transmitted. ‘Ans. 9, 130 and 13, 280mm, 24500 N Exercise 1.12 ‘Two 20° involute spur gears mesh externaly with a velocity ratio of 3 — the module is 3mm. and the addendum is equal to 1.1 module. if the pinion rotates at 120 rpm, determine (a) the minimum number of teeth on each wheel to avoid interference (b) the minimum and maximum number of pairs of teeth in contact. Ans. te=51, te=17; 1,2 Exercise 1.13 ‘Two 20° involute spur gears have a module of 10mm. The addendum is one module. The larger gear has 50 teeth and the pinion has 13 teeth. Prove that interference occurs and determine to what value the pressure angle should be changed to eliminate interference. Ans. 21.88" Exercise 1.14 A pinion of 20° involute teeth rotating at 275 rpm meshes with a gear and provides a gear ratio of 1.8. The number of teeth on the pinion is 20 and the module is 8mm. If the interference is just avoided, determine (a) the addenda on the gear and the pinion, (b) the Path of contact, and (c) the maximum velocity of sliding in both sides of the pitch point. Ans. 11.5mm, 27.34mm; 76.6mm; 1226mm/s, 2206mm/s Exercise 1.15 Apinion of 20° involute teeth and 125 mm PCD drives a rack. The addendum of both pinion and rack is 6mm.What is the least pressure angle that can be used to avoid undercutting? ‘With this pressure angle find the length of the arc of contact and the minimum number of teeth in contact at a time. ‘Ans. 35,9 mm, one pair 18Exercise 1.16 ‘Two mating gears have 20 (Pinion:Driver) and 40 (Gear:Driven) involute teeth of module 10mm and 20°presure angle. The addendum of each wheel is to be made of such a length that the line of contact on each side of the pitch point (P) has half the maximum possible length. Determine (a) the addendum height for each wheel, (b) length of the path of contact, (c) arc of contact and (d) contact ratio. Ans. 6.2mm ; $1.3mm ; 54.6mm ; 1.74 Exercise 1.17 A pair of spur gears with involute teeth is to give a gear ration of 4:1. The arc of approach is. not to be less than the circular pitch and the smaller wheel is the driver. The angle of pressure is 14.5°. Find: (a) the least number of teeth that can be used on each wheel, and (b) the addendum of the gear in terms of the circular pitch? Ans. 100; 0.27p. 19