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Chapter Outline

Shigley’s Mechanical Engineering Design

Types of Gears

Spur Helical

Bevel Worm
Figs. 13–1 to 13–4 Shigley’s Mechanical Engineering Design

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Nomenclature of Spur-Gear Teeth

Fig. 13–5 Shigley’s Mechanical Engineering Design

Tooth Size

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Tooth Sizes in General Use

Table 13–2

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Standardized Tooth Systems (Spur Gears)

Table 13–1

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Standardized Tooth Systems

 Common pressure angle f : 20º and 25º
 Old pressure angle: 14 ½º
 Common face width:
3p  F  5p

p
P
3 5
F
P P

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Conjugate Action
 When surfaces roll/slide
against each other and
produce constant angular
velocity ratio, they are said
to have conjugate action.
 Can be accomplished if
instant center of velocity
between the two bodies
remains stationary between
the grounded instant centers.

Fig. 13–6
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Conjugate Action
 Forces are transmitted on
line of action which is
normal to the contacting
surfaces.
 Angular velocity ratio is
inversely proportional to the
radii to point P, the pitch
point.

 Circles drawn through P

from each fixed pivot are
pitch circles, each with a
pitch radius.
Fig. 13–6
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Involute Profile
 The most common conjugate profile is the involute profile.
 Can be generated by unwrapping a string from a cylinder, keeping
the string taut and tangent to the cylinder.
 Circle is called base circle.

Fig. 13–8 Shigley’s Mechanical Engineering Design

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Involute Profile Producing Conjugate Action

Fig. 13–7 Shigley’s Mechanical Engineering Design

Circles of a Gear Layout

Fig. 13–9 Shigley’s Mechanical Engineering Design

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Sequence of Gear Layout

• Pitch circles in contact
• Pressure line at desired
pressure angle
• Base circles tangent to
pressure line
• Involute profile from
base circle
• Cap teeth at addendum
circle at 1/P from pitch
circle
• Root of teeth at
dedendum
circle at 1.25/P from Fig. 13–9
pitch circle
• Tooth spacing from
circular pitch, p =  / P

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Relation of Base Circle to Pressure Angle

Fig. 13–10 Shigley’s Mechanical Engineering Design

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Tooth Action
 First point of
contact at a
where flank of
pinion touches
tip of gear
 Last point of
contact at b
where tip of
pinion touches
flank of gear
 Line ab is line of
action
 Angle of action
is sum of angle
of approach and
angle of recess
Fig. 13–12 Shigley’s Mechanical Engineering Design

Rack
 A rack is a spur gear with an pitch diameter of infinity.
 The sides of the teeth are straight lines making an angle to the line
of centers equal to the pressure angle.
 The base pitch and circular pitch, shown in Fig. 13–13, are related
by

Fig. 13–13
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Internal Gear

Fig. 13–14

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Example 13–1

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Example 13–1

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Example 13–1

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Contact Ratio
 Arc of action qt is the sum of the arc of approach qa and the arc of
recess qr., that is qt = qa + qr
 The contact ratio mc is the ratio of the arc of action and the circular
pitch.

 The contact ratio is the average number of pairs of teeth in contact.

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Contact Ratio
 Contact ratio can also be found from the length of the line of action

 The contact ratio should be at least 1.2

Fig. 13–15 Shigley’s Mechanical Engineering Design

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Interference
 Contact of portions of
tooth profiles that are not
conjugate is called
interference.
 Occurs when contact
occurs below the base
circle
 If teeth were produced by
generating process (rather
than stamping), then the
generating process
removes the interfering
portion; known as
undercutting.

Fig. 13–16 Shigley’s Mechanical Engineering Design

Interference of Spur Gears

 On spur and gear with one-to-one gear ratio, smallest number of
teeth which will not have interference is

 k =1 for full depth teeth. k = 0.8 for stub teeth

 On spur meshed with larger gear with gear ratio mG = NG/NP = m,
the smallest number of teeth which will not have interference is

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Interference of Spur Gears

 Largest gear with a specified pinion that is interference-free is

 Smallest spur pinion that is interference-free with a rack is

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Interference
 For 20º pressure angle, the most useful values from Eqs. (13–11)
and (13–12) are calculated and shown in the table below.

Minimum NP Max NG Integer Max NG Max Gear Ratio

mG= NG/NP
13 16.45 16 1.23
14 26.12 26 1.86
15 45.49 45 3
16 101.07 101 6.31
17 1309.86 1309 77

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Interference
 Increasing the pressure angle to 25º allows smaller numbers of
teeth

Minimum NP Max NG Integer Max NG Max Gear Ratio

mG= NG/NP
9 13.33 13 1.44
10 32.39 32 3.2
11 249.23 249 22.64

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Interference
 Interference can be eliminated by using more teeth on the pinion.
 However, if tooth size (that is diametral pitch P) is to be
maintained, then an increase in teeth means an increase in
diameter, since P = N/d.
 Interference can also be eliminated by using a larger pressure
angle. This results in a smaller base circle, so more of the tooth
profile is involute.
 This is the primary reason for larger pressure angle.
 Note that the disadvantage of a larger pressure angle is an increase
in radial force for the same amount of transmitted force.

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Forming of Gear Teeth

 Common ways of forming gear teeth
◦ Sand casting
◦ Shell molding
◦ Investment casting
◦ Permanent-mold casting
◦ Die casting
◦ Centrifugal casting
◦ Powder-metallurgy
◦ Extrusion
◦ Injection molding (for thermoplastics)
◦ Cold forming

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Cutting of Gear Teeth

 Common ways of cutting gear teeth
◦ Milling
◦ Shaping
◦ Hobbing

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Shaping with Pinion Cutter

Fig. 13–17
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Shaping with a Rack

Fig. 13–18
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Hobbing a Worm Gear

Fig. 13–19 Shigley’s Mechanical Engineering Design

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