LAB REPORT 5

Objective: To practice 3D Drawing-03 which involves designing a spur gear with given
parameters and an involute teeth profile.

SolidWorks Fundamentals:
SolidWorks is a powerful and widely used 3D modeling software that allows users to
create complex models and assemblies. The software offers a comprehensive set of tools and
features for various applications, including product design, engineering analysis, and
manufacturing.

Designing a Spur Gear with Involute Teeth Profile:

 Applying gear design principles
 Utilizing SOLIDWORKS features for 3D modeling
 Creating realistic and functional mechanical components

Introduction:
Gears are fundamental components in various mechanical systems, responsible for transmitting
power and motion between shafts. Spur gears, with their straight and parallel teeth, are the most
common type and offer simplicity in design and efficient power transmission. Designing these
gears requires understanding their key parameters and applying proper modeling techniques.

Gear Fundamentals:
2.1 Definition of Gear:

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A gear is a rotating wheel with teeth that mesh with another gear, allowing for the transfer of
power and motion between shafts. Gears come in various types, each with unique tooth profiles
and applications.

2.2 Spur Gear Characteristics:

Spur gears are characterized by the following:
 Straight teeth: These run parallel to the axis of rotation, providing simplicity in design
and ease of manufacture.
 Constant velocity ratio: The ratio of rotational speeds between the mating gears remains
constant, providing smooth and predictable motion.
 High efficiency: Spur gears offer efficient power transmission, making them suitable for
various applications.

2.3 Key Parameters:

Designing a spur gear requires defining several key parameters:
The involute profile is most common used in Gear designed and is generated from base
circle. There are many ways to create gear and many times we ignore the standard construction
method to save time. This should be avoided. So I have created this model which is equation
driven.

That means we only need 4 parameters to define the whole spur gear design.
1. Number of Teeth
2. Module
3. Pressure Angle (usually 20o) take from the textbook of Machine Design
4. Face Width

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  Module (m): This defines the gear's size and dictates the relationship between other
dimensions.
 Number of teeth (N): This determines the gear's rotational speed and torque.
 Pressure angle (α): This defines the angle of contact between the teeth, influencing their
strength and wear characteristics.
 Face width (b): This specifies the width of the gear, impacting its load-carrying capacity.
 Bore diameter (d): This defines the size of the hole in the gear that fits onto the shaft.

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Involute Teeth Profile:
The involute profile is the standard for gear teeth due to its several advantages:
 Smooth engagement: This allows for quiet and efficient power transmission.
 Constant velocity ratio: This ensures predictability and stability in motion.
 Ease of manufacture: The involute equation defines the tooth profile mathematically,
simplifying the manufacturing process.

Commands to be used:
 Circle Command
 Line Command
 Offset Command
 Arc Command
 Sketch Fillet Command
 Mirror Command
 Extend Command
 Circular Sketch Pattern Common
 Trim Command
 Extrude Command

Modeling Parametric Spur Gear in Solidworks:

Spur gears have teeth parallel to the axis of rotation used in the transmission
of motion between parallel shafts. Considered the simplest gear, it is used to develop the primary
kinematic relationships of the tooth form. The pitch circle isa theoretical circle upon which all
calculations are usually based. The diametral pitch P is the ratio of the number of teeth on the
gear to the pitch diameter. Thus, it is the reciprocal of the module in the metric system
(ISO).Since diametral pitch is used only with U.S. units, it is expressed as teeth per inch. In
general uses:

 Coarse: 2, 2.25, 2.5, 3, 4, 6, 8, 10, 12, 16

 Fine: 20, 24, 32, 40, 48, 64, 80, 96, 120, 150, 200

Addendum (a): The radial distance from the pitch circle to the top of the gear tooth:

Dedendum (b): The radial distance from the pitch circle to the bottom of the tooth.
Dedendum = Addendum + Clearance

Pitch circle diameter(dp) is the diameter of the pitch circle from which the
gearis designed. It’s an imaginary circle, which will contact the pitch circle of another

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 gear when mesh. Moreover, it is defined for each gear as a relation between the number
of teeth (N) and diametral pitch.

Base circle diameter(db) is the circle used to form the involute section of the gear tooth.
Pressure angle(α) is the angle between the tangent to the tooth profile in an axial plane at
the pitch surface and a line perpendicular to the axis. It’s usuallyα = 20°.With the
equation tool in SolidWorks, it is possible to write all of the global variables and evaluate
the dimensions as a calculation page and solve any change if any variable in the formulas
change too.

Clearance (c): It is the radial distance from the top of the tooth to the bottom of the
tooth, in a meshing gear. A circle passing through the top of the meshing gear is known
as clearance circle.
It is the ratio of circular pitch pc to the number of teeth on gear.
Clearance = pc/T

Dedendum Circle Diameter: It is defined as: D – 2.(Dedendum)

Circular Pitch Angle: It is defined as: (pc × 360)/(π × D × 4)

Backlash (B): It is the difference between the tooth space and the tooth thickness, as
measured on the pitch circle.

SOLIDWORKS Modeling:

SOLIDWORKS offers various features and tools for creating accurate and detailed 3D models:
 Sketching: This allows for defining the gear's tooth profile based on the involute
equation and other dimensions.
 Extrude: This extrudes the single tooth profile along the face width to form the entire
Gear body.

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  Fillet and chamfer: These features add rounded edges to improve stress distribution and
enhance aesthetics.
 Bore and keyway: These features create the necessary holes and slots for mounting the
gear on a shaft.

Step-by-Step Design and Modeling Process:

1. Define Gear Parameters:
Choose appropriate values for module, number of teeth, pressure angle, face
width, and bore diameter based on the desired application.
2. Calculate Gear Geometry:
Use formulas to determine the addendum, dedendum, clearance, whole depth,
outside diameter, and root diameter based on the selected parameters.
3. Sketch Single Tooth Profile:
Use SOLIDWORKS sketch tools to create a single tooth profile considering
the involute equation and calculated dimensions.
4. Extrude Gear Body:
Extrude the single tooth profile along the face width to generate the full gear
body.
5. Add Additional Features:
Include the bore, keyway (if required), fillets, and chamfers to complete the
design.
6. Perform Stress Analysis :

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 Utilize SOLIDWORKS Simulation tools to analyze the stress distribution on
the gear under anticipated loads.

Drawing Procedure:
1. Pick part option from new Solidworks document dialogue box, select front plane and
enter sketch mode by picking sketch option.

2. Pick equations from tools menu.

3. Define global variables, calculate their values, add description in comment section
about them and click ok.

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 4. Set the sketch normal to plane and construct a circle of dimension equal to calculated
value of pitch circle diameter. To do this, pick parameter Dp from dimension dialogue
box . Select circle command and sketch addendum and dedendum circle and mention
dimensions. And Make all the sketched circles as construction circles. Sketch a base
circle by drawing a tangent circle to two drawn construction lines at circumference of
pitch circle with angle between them equal to pitch angle. Mention “Base Circle” as
dimension text to differentiate it from other.

5. Draw two lines, make them equal and turn them as construction lines. From an ending
point of constructed line, create a little extended tangent line to base circle, divide that
line into three equal parts and make them construction lines. In this way four line
segments would be created.

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6.Use mirror entities command and mirror the sketched arc which we used to indicate
backlash.

7. Use offset entities and trim entities commands to turn the sketched optimum circles into
desired shape in order to create a central hole.

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On front plane, create new sketch and use convert entities command to copy the tooth
profile to new sketch.
8.Apply fillet on the teeth.

9.Use circular sketch pattern, provide axis of rotation, select entities to pattern and enter
number of pattern according to number of teeth.
10. Add extruded bass feature by selecting all the teeth as contours.

3D Drawing Final:

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Conclusion:
This exercise provides hands-on experience in designing and modeling a functional spur gear
with involute teeth profile using SOLIDWORKS. Through this process, participants gain
valuable knowledge in gear design principles and develop their 3D modeling skills. This
knowledge and skillset will prove beneficial for future projects involving mechanical component
design and creation.
Further Exploration:
 Explore additional SOLIDWORKS features and functionalities for advanced modeling
and design.
 Analyze the gear's performance under various loading conditions using SOLIDWORKS
Simulation tools.
 Research advanced gear design concepts and incorporate them into future projects.
 Consider learning more about other gear types and their applications.

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