EXPERIMENTS NO -1

Aim:
a).To study gear train arrangement of a gear box.
b).To study different types of gears.
Objective:

a). To study the gears train arrangement and to find out the velocity ratio of each gear
position.
b). To study different types of gears.
Theory:

HELICAL GEARS

Helical gears have their teeth inclined to the axis of the shafts in the form of a helix,
hence the name helical gears.
These gears are usually thought of as high speed gears. Helical gears can take
higher loads than similarly sized spur gears. The motion of helical gears is smoother
and quieter than the motion of spur gears.
Single helical gears impose both radial loads and thrust loads on their bearings and
so require the use of thrust bearings. The angle of the helix on both the gear and the
must be same in magnitude but opposite in direction, i.e., a right hand pinion meshes
with a left hand gear.
If gears have two sets of opposed helical teeth are double helical gears. In the double
helical gears arrangement, the thrusts are counter-balanced. In such double helical
gears there is no thrust loading on the bearings.

DIFFERENTIAL GEAR

A differential gear is an arrangement of beveled

gears in such a manner such that the input torsion is
taken up by a ring gear and distributed equally
through two planetary gears to the side gears which
drive the shafts on either side.
One of the common applications of differential gears is in
automobiles. Consider a vehicle following a curved path.
As one can easily imagine, the inner wheel covers a
shorter distance than the outer wheel. In case the system
consists of only a single shaft connecting the inner and
outer wheel, both the wheels are forced to turn at the
same angular momentum and hence makes turning
difficult leading to slippage and binding of tires. In
addition to this, the strain on the inner wheels is passed
on to the outer wheels through the axle putting undue
strain on it.
This problem is solved by using the differential gear
system. In this, the power of the engine is transferred
through a drive shaft and pinion arrangement to the
ring gear and the torque is further split by the
differential gears into two components such that the
outer wheel spins at greater angular momentum than
the inner wheel. This eliminates slippage of the wheels
and strain on the axle.

HYPOID GEARS

Gears are major part of any machine working on the principle of rotary motion. The
motion can be produced either by a motor or engine and is called the input. The engine
usually has a very high angular momentum but the torque is small. This torque is not enough
for performing work under heavy load and hence cannot be used directly in industrial
machines. To overcome this problem, coupled gears are used.
In coupled gear system, the input is connected through a driving shaft to a small gear
called the pinion. The pinion is further coupled with a gear of larger diameter i.e. high gear
ratio. Due to this form of coupling, the torque of the engine increases at the expense of
angular momentum. A variety of gears can be used for this purpose viz. spur gears, helical
gears, worm gears, etc.
However these gears have a limitation i.e. they can only be used in systems where
the input and output shafts are in the same plane. To overcome this problem, a special
type of gear called the hypoid gear is used.
The hypoid gears are a subtype of bevel gears. On observation the hypoid gear
seems to be similar in appearance to the helical bevel gears. The main difference being
that the planes of the input and the output gears are different. This allows for more
efficient intermeshing of the pinion and driven gear. Since the contact of the teeth is
gradual, the hypoid gear is silent in operation as compared to the spur gears
These gears are usually used in industrial and automotive application and hence the
material used is a metal like stainless steel. A major application of hypoid gears is in car
differentials where the axes of engine and crown wheel are in different planes.

WORM GEAR AND WORM WHEEL

Worm gear drives offer many benefits. They take up little space, offer quiet operation
and have been used in many different applications. Worm gear drives provide extreme
benefits where size is problem Traditional spur gears would take up considerably more room
than what can be accomplished with a simple worm gearbox. They also take advantage of all
the major forms of gearing to suit almost any application.
Worm gear drives offer great operation for many different uses. You'll find them in
use in use in the mining industry, in ship's rudders and all types of presses. Worm drives
offer a great way to amplify a limited amount of torque, though heat can cause them to
become less efficient. Worm gears are also used in a limited amount of automotive
differentials, though it has fallen out of favor with many manufacturers. Hummer is one of
the manufacturers that still utilize worm gears in their differential, specifically their military
vehicles, though some civilian applications have worm gears, as well.
Worm gears were replaced in open differential due to problems with reduction ratios,
though many all wheel drive vehicles continue to use worm gear drives in their
applications. Large trucks used for hauling very heavy loads often utilize worm gear drives
in their differentials, though they require very large differential housings to accommodate
the amount of differential fluid needed to dissipate the heat created by the worm gear drive
itself.
A worm gear drive consists of two main parts: the worm gear itself, which looks
much like a spur gear and the worm, which is a gear shaped like a screw. The benefits
that a worm gear drive offers are due to the fact that each revolution of the worm turns
the worm gear a whole tooth; this allows them to greatly amplify

torque in their relative settings.

Possibly the single best example of a worm gear is the adjustable screw clamp, called
a jubilee clamp. These are found almost everywhere and most people are familiar with their
appearance. Other forms of the worm gear drive exist, but this is the single most
recognizable form that they take. The best applications for a worm gear drive are those in
manufacturing industries where greater torque, in a smaller package is required. Since the
worm gear drive is able to be set up at right angles to the input shaft, the length of the
equipment is significantly reduced. Many industries find that the non-reversible motion is a
great benefit, as well. Since the worm can only drive the gear, it means that they can only be
used as speed reducers, rather than speed enhancers. The gear cannot drive the worm in a
worm gear drive.
Due to these factors, they are an ideal way of decreasing speed, yet increasing
power in smaller equipment. While there are many different applications for worm gear
drives around the world today, small electric motors are possibly the area that they benefit
the most, though musical instruments have been the longest running beneficiary of these
devices.

SPUR GEAR

Parallel and co-planer shafts connected by gears are called spur gears. The arrangement is
called spur gearing.
Spur gears have straight teeth and are parallel to the axis of the wheel. Spur gears are
the most common type of gears. The advantages of spur gears are their simplicity in
design, economy of manufacture and maintenance, and absence of end thrust. They
impose only radial loads on the bearings.
Spur gears are known as slow speed gears. If noise is not a serious design problem,
spur gears can be used at almost any speed.
A common arrangement of spur gears is an external gear and pinion combination. If the
centre distance has to be reduced, then internal gear and external pinion

RACK AND PINION

The rack and pinion is used to convert between rotary and linear motion. The rack is the flat,
toothed part, the pinion is the gear. Rack and pinion can convert from rotary to linear of
from linear to rotary.
The diameter of the gear determines the speed that the rack moves as the pinion turns. Rack
and pinions are commonly used in the steering system of cars to convert the rotary motion of
the steering wheel to the side to side motion in the wheels.
Rack and pinion gears give a positive motion especially compared to the friction drive of a
wheel in tarmac. In the rack and pinion railway a central rack between the two rails engages
with a pinion on the engine allowing the train to be pulled up very steep slopes.

BEVEL GEARS

Bevel gears are useful when the direction of a shaft's rotation needs to be changed. They
are usually mounted on shafts that are 90 degrees apart, but can be designed to work at
other angles as well.
A good working example of a bevel gear is the mechanism used in a hand drill. As you turn
the handle of the drill in a vertical direction, the bevel gears change the rotation of the chuck
to a horizontal rotation. The bevel gear also works to increase the speed of the chuck so that
its possible for the drill to work on a range of surfaces.
There are four types of bevel gears:
Straight Bevel Gears: These gears have a conical pitch surface and straight teeth tapering
towards an apex.
Zero Bevel Gears: Are very similar to straight bevel gears except the teeth are curved.
Spiral Bevel Gears: The teeth are curved at an angle which then allows the contact to be
gradual and smooth.
Hypoid Bevel Gears: These gears are similar to spiral bevel except that the pitch surfaces are
hyperboloids rather than cones and the gears can be anti backlash.

Observation and Results:

a). Find out the different velocity ratio of a gear box by engagement of different gears.
b). Draw the individual gear positioning system of the gear box.
Explain mechanical power transmission and applications of different types of gear.
Study the