Machine engineering - Lecture 7

GEARS
Lecturer: Bernard Heikema (HEBE)
Contents
Gears
• Kinematics of gears
(Mott sections 8-1 thru 8-5 + 8-11)
• Spur gear design
(Mott sections 9-1 thru 9-3 + 9-10 excl
stress analysis)
Gears
Why gears?
• Mismatch motor / driven machine
• Change Torque / speed
• Reverse direction
• Accurate positioning
(e.g. a crane tub)
• Etc.

General layout of a saw machine with single-stage gear reducer

Types of gears
Types of transmissions
• Roll-transmission
• Roll-screw-transmission
• Screw-transmission

Types tandwieloverbrengingen

Types of gears
Spur gear styles
History & Tooth forms
Types:
• Pin wheel gear (old Dutch windmills)
 History & Tooth forms
Types:
• Pin wheel gear (old Dutch windmills)
• Cycloid tooth form (Precision manufacturing, clocks, measuring tools, high manufacturing
costs)
History & Tooth forms
Types:
• Pin wheel gear (old Dutch windmills)
• Cycloid tooth form (Precision manufacturing, clocks, measuring tools, high
manufacturing costs
• Involute tooth form (machine engineering, most common)

Base
circle
Spur gear nomenclature and gear-tooth features
Diametrical Pitch System (U.S. system of units) versus Metric Module System

Nomenclature:
• Pinion (P) and Gear (G)

• Addendum circle with outside diameter Do

• Pitch circle with pitch diameter D
• Dedendum circle with root diameter DR
• Number of Teeth N
• Circular pitch [in or mm]: p = π·DP /NP =
π·DG /NG

Diametrical pitch [teeth/in]: Pd = NP /DP = NG /DG

Or:
Metric module [mm]: m = DP /NP =
DG /NG
Spur gear nomenclature and gear-tooth features
Nomenclature:

• Pinion (P) and Gear (G)

• Addendum circle with outside diameter Do

• Pitch circle with pitch diameter D

• Dedendum circle with root diameter DR

• Number of Teeth N

• Circular pitch [in or mm]: p = π·DP /NP = π·DG /NG

Diametrical pitch [teeth/in]: Pd = NP /DP = NG /DG

Or:

Metric module [mm]: m = DP /NP = DG /NG

Spur gear nomenclature and gear-tooth features
Tooth properties based on metric module:

• Addendum: a=m
• Clearance: c = ¼·m
• Dedendum: b=m+c
= m + ¼·m = 1.25·m

• Tooth depth: ht = a+b

= 2.25 · m
• Working tooth depth: hk ≈ 2.00 · m
• Tooth thickness: t = π·m/2

• Face width F  12·m (8·m < F

< 16·m)
• angle
The pressure Pressure angle
”φ” is the angle φ the
between the tangent to the pitch circles and (use φ =normal
line drawn 20⁰)
• toCircular
(perpendicular) the surface ofpitch:
the gear tooth p=π·m
Spur gear nomenclature and gear-tooth features

Diameter properties based on metric module:

• Pitch diameter:
D = N·m

• Outside diameter:
Do = D+2·m = N·m + 2·m = (N+2)·m

• Root diameter:
Dr = D - 2.5·m = N·m - 2.5·m = (N-2.5)·m

• Center distance:
C = ½·(DP + DG) = ½·m·(NP + NG)
 Line of action

Base circle 1 Base circle 2

Pitch circle 1 Pitch circle 2
Top circle 1 Top circle 2
Spur gear nomenclature and gear-tooth features
• Base Circle diameter Db : Db = D · cos φ

• Contact ratio mf :
mf = average number of teeth in contact during transmission of power
= line of action / length of action

Mott: all in inches

 m

all in mm
• mf > 1.2 (often you see mf > 1.5)
 Spur gear nomenclature and gear-tooth features
Nomenclature:
Center distance: C = ½·(DP + DG) = ½·m·(NP + NG)

Backlash: Cutting deeper into the gear blank

or:
Increase center distance to provide positive play
between mating teeth.
Interference between mating spur gear teeth
Occurs:
• Because cutter tool removes part of
the tooth profile (P)
• Happens with small number of teeth
(P)

Results in:
• Shortening of the line of action
• Weakens tooth base
Interference between mating spur gear teeth

Occurs:

• Because cutter tool removes part of the tooth profile (P)

= Undercutting

• Happens with small number of teeth (P)

Results in:

• Shortening of the line of action

• Weakens tooth base

Interference between mating spur gear teeth
Interference can be solved by:
• Minimizing the number of pinion teeth
Interference between mating spur gear teeth
Interference can be solved by:
• Shift of tooth profile
Interference between mating spur gear teeth
Interference can be solved by:
• Shift of tooth profile

Note: Changing center distance of

involute gears changes only the
pressure angle and pitch diameters,
 Gear rack - Features
Rack:
• Gear with infinite diameter
• Pinion – Involute tooth form
• Pressure angle = 20°
Adequate gearing Line of action

Adequate gearing requires:

• Smooth running
• Constant Velocity Ratio:

VR = ω1 / ω2 = r2 / r1 = N2 / N1 = constant

• The gear contact points follow the line of

action
• The line of action is the tangent to the
base circle of both gears
• If friction is neglected, the contact forces
point at pole C. Base circle 1 Base circle 2
• Both contact points have different linear Pitch circle 1 Pitch circle 2
Top circle 1 Top circle 2
speeds  teeth roll and slide on each
other
 Line of action

Base circle 1 Base circle 2

Pitch circle 1 Pitch circle 2
Top circle 1 Top circle 2
 Line of action

Base circle 1 Base circle 2

Pitch circle 1 Pitch circle 2
Top circle 1 Top circle 2
 Line of action

Wn

Base circle 1 Base circle 2

Pitch circle 1 Pitch circle 2
Top circle 1 Top circle 2
 Line of action

Wn Wt
M1

r1

Wr

Force of constant magnitude independent of position of teeth  Smooth running

Forces, torque and power in gearing
Pitch line speed (US): vt = π ∙ D ∙ n /12 [ft/min]

Tangential force (US): Wt = 126000 ∙ P/ (n ∙ D) [lb]

Torque (US): T = 63000 ∙ P / n [lb∙in]

(n = Rotational speed [rpm] , P = Power [W])

Pitch line speed (SI): vt = π ∙ D ∙ n / 60000 [m/s]
Tangential force (SI): Wt = P / vt = 60000 ∙ P / (π ∙ n ∙
D) [N]
Torque (SI): T = P / ω = 30 ∙ P / (π ∙
n) [N∙m]

Radial force: Wr = Wt ∙ tan φ

Normal force: W = W / cos φ
Efficiency
Power in

Efficiency (roughly): Gear transmission

ηZ = 0,99 (spur gear) Rolling & sliding tooth

flanks

ηL = 0,99 (per shaft with 2 roll bearings) Bearing friction

Shaft seals
ηD = 0,98 (per shaft)

Lubrigation

Transmission with 2 shafts: ηtot = 0,99 • 0,992 • 0,982 ≈ 0,93

Power out
 Manufacturing - Involute tooth form
Methods:
• planer machine and a rack-shaped planer tool
(chisel)

• Hobbing/Milling

• Laser / Waterjet cutting

• 3D printing
Gear: Make or Buy?
Various methods
Example
A gear pair is to be designed to transmit 15.0 kW of power to a large meat grinder in
a commercial meat processing plant.
The pinion is attached to the shaft of an electric motor rotating at 575 rpm. The gear
must operate at 270 to 280 rpm.
The gear unit will be enclosed and of commercial quality. Commercially hobbed
(quality number A11), pressure angle φ = 20⁰, full depth, involute gears are used in
the metric module system. The maximum center distance is to be 200 mm.
Please specify the geometry of the gears.

Solution:
Nominal velocity ratio is: VR = 575/275 = 2,09
Solution (cont’d)
A gear pair is to be designed to transmit 15.0 kW of power to a large meat grinder in
a commercial meat processing plant.
The pinion is attached to the shaft of an electric motor rotating at 575 rpm. The gear
must operate at 270 to 280 rpm.
The gear unit will be enclosed and of commercial quality. Commercially hobbed
(quality number A11), pressure angle φ = 20⁰, full depth, involute gears are used in
the metric module system. The maximum center distance is to be 200 mm.
Please specify the geometry of the gears.

Electrically driven  Uniform power source

Meat grinder  Moderate shock
So, overload factor Ko = 1.5
and design power amounts to:
Pdes = Ko · P = 1.5 · 15.0 = 22.5 kW
Solution (cont’d)
Pinion speed nP = 575 rpm
Pdes = Ko · P = 1.5 · 15.0 = 22.5 kW
22.5 kW
Figure 9-11 gives as a reasonable trial
module: m=5

575 rpm
Solution (cont’d)
Take number of teeth of pinion: NP = 18 teeth (see table 8-7)
The pinion pitch diameter becomes: DP = 18 · 5 = 90 mm
And number of gear teeth becomes: NG = NP · VR = 18 · 2.09 = 37.6
So, use: NG = 38
teeth (VR = 2.11)
Then the gear pitch diameter becomes: DG = 38 · 5 = 190 mm
Final output speed: nG = 575 rpm ·
18/38 = 272 rpm OK
Center distance: C = ½·m·(NP + NG) = ½· 5·(18+38) = 140 mm
OK
Pitch line speed: vt = π ∙ DP ∙ nP / 60000 = π ∙ 90 ∙ 575 / 60000 =
2.71 m/s
Tangential force: Wt = P / vt = 22500 / 2.71 = 8303 N
Radial force: Wr = Wt ∙ tan φ = 3022 N
Solution (cont’d)

F = 50 mm = 10·m OK (8·m < F < 16·m)

Materials for gears
Materials:
• No optimal lubrigation  metal / metal contact
• Unhardenened tooth flanks: choose a large
difference in hardness
• Hardened and grinded tooth flanks: not required
• Pinion (small), choose strongest material
(usually steel)  why??
• Gear (large) cast iron or steel (depending on
loadings)
 ,,
,,

Lubrigation of gears
Lubrigation for:
• Preferably full fluid film lubrication
• However usually boundary lubrication because of
sliding and rolling motions
• Minimising friction
• Minimising wear Source: Tribology in joint replacement

• Improving efficiency W. Cui, Z. Jin, J. Fisher

• Discharge of heat
(using liquid lubrication)

Source: Electrochemical Instrumentation of a Hip Simulator: A New Tool for Assessing

the Role of Corrosion in Metal-On-Metal Hip Joints

Y Yan, A Neville, D Dowson, S Williams and J Fisher

Faling mechanisms for gears
Failure due to:

• Grinding, interruption of fluid film layer due to high

contact pressure

• Broken tooth, bending moment at tooth base too high

optionally in combination with fatigue

• Pitting, surface pressure on tooth flank too high

Selection of a gearbox
E.g. find an adequate
gearbox for this pump
spread:
Couplings
Dieselengine
Velocities:
Motor: 1800 rpm
Pomp: 900 rpm Ballastpump

Power:
Motor: 65 kW
Pump: 58,2 kW

Skid Gearbox
Selection of a gearbox

Various manufacturers
Selection of a gearbox
• Download catalogues of various manufacturers
• Follow the design procedures from the catalogue:
• Determine basic data (P, n, i, )
• Determine factors (service factor,
peak factor, startup factor)
• Compute nominal power
• Check nominal power
• Determine peak loading
• Determine allowable peak loading
• Check peak loading
• Check thermal rating
• Check extra external loadings
Selection of a gearbox
• Succes…
End