L. D.

College of Engineering College,

Ahmedabad

Design of Machine Elements and Transmission System (3144101)

Lecture_1
Design of Spur Gear-1
(Fundamentals)

Prof. Mahendra Y Patil

Asso. Prof. Mechanical Engineering
Mechanical Engineering Department

Program:- BE (Robotics & Automation) Sem: 4

 Learning Outcomes

Students will be able to :

 Understand the functions of gear,

 Classify the gears,

 Understand the use of gears in basic power transmission,

 Understand the law of gearing,

 Understand the basic terminology of gears

 Understand the phenomenon of Interference, Undercutting

and backlash in gears.

 Analyze the forces acting on Spur Gears.

 Introduction to Gears

 Gears are machine elements used for the transmission of

motion and power from one shaft to another by
progressive engagement of teeth.
 Gear drive is a positive drive and the velocity ratio
remains constant.
 Advantages of Gear drives over other drives;
 Gears can transmit very large power,
 can be operated at very low speeds,
 have very high efficiency and
 require lesser space in comparison to the belt and
chain drives.
 Classification of Gears
• Parallel axis gears:
– spur gears
– helical gears
– internal gears
• Non-parallel, coplanar gears (intersecting axes)
– bevel gears
• Miter Gear
• Straight bevel gear
• Spiral bevel gear
– face gears
• Non-parallel, non coplanar gears (non-intersecting axes):
– crossed axis helical
– cylindrical worm gearing
• single enveloping worm gearing
• double enveloping worm gearing
– hypoid gears
• Special gear types:
– square and rectangular gears
– elliptical gears
Types of Gears
Basic Ides of Power Transmission using Gears
 Law of Gearing
• Statement 1: The fundamental law of gearing states ‘The common
normal to the tooth profile at the point of contact should always pass
through a fixed point, called the pitch point, in order to obtain a
constant velocity ratio.

• Statement 2: The angular velocity

ratio between 2 meshing gears
remains constant throughout the mesh.
 Terminology of Spur Gears
The below diagram shows the various terminologies used in spur gear.
 Terminology of Spur Gears continue…
The below diagram shows the various terminologies used in spur gear.

• Velocity Ratio: Velocity ratio is the ratio of angular velocity of the

driving gear to the angular velocity of the driven gear. It is also called
the speed ratio.
• Transmission Ratio (i’) The transmission ratio is the ratio of the
angular speed of the first driving gear to the angular speed of the last
driven gear in a gear train.
 Terminology of Spur Gears continue…
• Circular Pitch: The circular pitch (Pc) is the distance measured along
the pitch circle between two similar points on adjacent teeth.
Pc = π*d /Z where Z is the number of teeth.
• Diametral Pitch: The diametral pitch (Pd) is the ratio of the number of
teeth to the pitch circle diameter.
Pd = Z/d
Pc * Pd = π
• Module:The module (m) is defined as the inverse of the diametral pitch.
m = 1/Pd = d/Z Pitch circle Dia. (PCD)=d = m*Z
• Centre Distance (a): The centre to centre distance between two gears
having Zp and Zg teeth is given by
a = (dp + dp)/2 = (m Zp + m Zg)/2 = m/2 (Zp + Zg)
• The gear ratio (G): that is, the ratio of the number of teeth on gear to
that on pinion is given by,
G = Zp / Zg = Np / Ng
Np & Ng Speed of pinion and gear
 Standard Systems of Gear Tooth
The involute profile is most preferred over others for gear
tooth because of following reasons:
(i) The involute profile satisfies the fundamental law of
gearing at any centre distance.
(ii) All involute gears of a given module and pressure angle
are completely interchangeable.
(iii) All involute gears of a given module and pressure angle
can be machined from one single tool.
(iv) The basic rack of an involute profile has straight sides.
It is comparatively easy to machine straight sides.
Further, straight sides can be more accurately
machined compared with a curved surface.
(v) In involute gears, the pressure angle, from the start of
the engagement of teeth to the end of the engagement,
remains constant. It is necessary for smooth running
and less wear of gears.
 Standard Systems of Gear Tooth continue..
There are three standard systems for the shape of gear teeth. They are as
follows:
(i) 14.5° full depth involute system
(ii) 20° full depth involute system
(iii) 20° stub involute system
 Standard Systems of Gear Tooth continue..
The 20° pressure angle system has the following advantages over
the 14.5° pressure angle system:
(a) It reduces the risk of undercutting.
(b) It reduces interference.
(c) Due to the increased pressure angle, the tooth becomes
slightly broader at the root. This makes the tooth stronger
and increases the load carrying capacity.
(d) It has greater length of contact.
 Interference
Contact of portions of tooth profiles that are not conjugate is called
interference.
It occurs when contact occurs below the base circle.
The tip of the tooth on the mating gear, which is involute, interferes with
this non-involute portion of the dedendum. This phenomenon of tooth
profiles overlapping and cutting into each other is called ‘interference’.
It is maximum when the smallest pinion is in mesh with the largest
gear.
• Methods of eliminating interference:
(i) Increase the Number of Teeth on the Pinion
Increasing the number of teeth increases the
size of the gearbox and also increases the
pitch line velocity. This is not desirable.
(ii) Increase Pressure Angle This results in smaller base circle so that more
portion of the tooth profile becomes involute.
(iii) Use Long and Short Addendum Gearing In this method, the addendum of the
pinion is made longer than the standard addendum. Also, the addendum of the
mating gear is made shorter than the standard addendum. However, this
results in non-standard and non-interchangeable gears.
 Backlash
Backlash is the amount by which width of a tooth space exceeds the
thickness of mating tooth.
Objectives of providing backlash:
 (i) Provided to avoid jamming of the mating teeth, (ii) to compensate for
machining errors and (iii) thermal expansion of teeth.
 It is provided by cutting the gears thinner or by slightly increasing the centre
distance. This has no effect on the tooth action or velocity ratio.
 Backlash should be minimum, when gears to be used in precision equipment.

Methods to provide backlash:

(i) The teeth of the gear are cut slightly thinner.
This is obtained by setting the cutting tool
deeper into the blank resulting in thinner
tooth and wider space.
(ii) The centre distance between mating gears is
slightly increased.
The magnitude of recommended backlash depends upon the diametral pitch
or module and the centre distance.
The magnitude of backlash is very small for gear trains used in precision
equipment and instruments.
 Force Analysis of Spur Gears
In gears, power is transmitted by means of a force exerted by the
tooth of the driving gear on the meshing tooth of the driven gear.
Figure (A) Gear Toot Force Figure (B): Components of Gear Tooth Force
 Force Analysis of Spur Gears continues
According to the fundamental law of gearing, this resultant force PN always
acts along the pressure line.
The resultant force PN can be resolved into two components
(i) tangential component Pt and (ii) radial component Pr
at the pitch point as shown in Figure.
(i) Tangential Force (Pt) : is a useful load because it determines the
magnitude of the torque and the power transmitted.
(ii) Radial component (Pr) : acts towards the centre of the gear, so also
called as separating force.
Torque transmitted T = Pt * Radius = Pt * d/2, d is PCD of gear.
Power P = 2 π N T / 60, so T can be calculated.
From the fugure;
Pr = Pt Tanα………..(i)
Pt = 2 T/ d…………..(ii)
 References
1) V.B. Bhandari,” Design of Machine Elements,”Mc Graw Hill
Education, Third Edition, 2014.
2) Robert L Norton, Machine Design An Ïntegrated Approach,
Pearson”, Second Edition, 2014
3) R G Budynas, and K J Nisbett, Shigley's Mechanical Engineering
Design, McGraw-Hill
4) R C Juvinall, Fundamentals of Machine Component Design, 4/e,
Wiley.
5) R S Khurmi, J K Gupta, “Machine Design,” EURASIA PUBLISHING
HOUSE (PVT.) LTD. RAM NAGAR, NEW DELHI-110 055, 14th
Edition, 2005
6) P C Gope, Machine Design: Fundamentals and Applications, 1/e
PHI.
7) K Hoga, B Dondlinger, Vehicular Engine Design, Springer.
Q&A
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Quiz