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Module 2 - GEARS
Lecture 4: WORKED OUT PROBLEMS ON INVOLUTE SPUR GEARS
Content
4.1 Introduction
4.2 Gear Calculation -Worked example 1
4.3 Gear Calculation -Worked example 2
4.1 INTRODUCTION
In the earlier lectures, the definition of gear, gear terminology, interference, methods of
eliminating interference, standard tooth systems for spur gears, profile shifted gears,
involutometry and design of gear blanks were dealt in detail. With the background of the
above knowledge, solving of simple gear problems will be dealt in this lecture.
i = 2.5;
C = 70 mm; = 20o;
Given Data:
To be found:
m = ?;
Z1 = ? ;
d1 = ?;
Z2 = ?;
d2 = ?;
CR = ?
We know that,
C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1) = 70 mm
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Machine Design II
i.e., m x Z1 = 40
Possible solutions for standard modules as can be seen from the table:
Solution I:
d1 = m Z1 = 2 x 20 = 40 mm
d2 =i d1 = 2.5 x 40 = 100 mm
0.4
0.5
0.6
0.7
0.8
1.0
1.25 1.5
1.75
2.0
2.25
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
10
11
12
13
14
15
16
18
20
22
24
26
28
30
33
36
39
42
45
Minimum number of teeth that can engage with the gear of 50 teeth without
interference is given by,
z12 + 2 z1 z2 =
4k(z2 + k)
sin 2
For full depth gears, k = 1. Substituting the values Z2 = 50, = 20o in the above
equation,
z12 2 z1 x50
4 x 1( 50 1 )
sin 2 20 o
z 2 + 100 z 1744 0
1
1
Since from the above it is seen that, Z1 > Z1min no interference will occur.
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Machine Design II
La = ua + ur
L ( r a )2 r 2 cos 2
a
1
1
( r a )2 r 2 cos 2 ( r r ) sin
2
2
1 2
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Machine Design II
CR
L
L
9.798
9.798
a
a
1.660
p cos m cos x 2 x cos 20o
5.901
For full depth tooth, the various values calculated are as shown below:
Addendum:
a = 1m = 1x2
= 2mm
Dedendum:
Clearance:
c = 0.25 m = 0.25x2
= 0.5 mm
Solution II:
The centre distance is given by, C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1)
= 70 mm
Simplifying, m x Z1 = 40
Another possible solution for standard module from the table is,
m = 2.5 mm, Z1 = 16, Z2 = i x Z1 = 40,
d1 = m Z1 = 2.5x16=40 mm,
d2 = m Z2 = 2.5 x 40 =100 mm
Minimum number of teeth that can engage the gear of 40 teeth without interference
is given by,
z12 + 2 z1 z2 =
4 k (z2 + k)
sin 2
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Machine Design II
For full depth gears k = 1. Substituting Z2 = 40, = 20o, in the above equation,
4(40 + 1 )
z 2 + 2 z x 40 =
1
1
sin2 20o
z 2 + 80 z 1402 0
1
1
Contact ratio, CR :
Referring to the fig. 4.1, the path of contact is given by,
La = ua + ur
L ( r a )2 r 2 cos 2
a
1
1
( r a )2 r 2 cos 2 ( r r ) sin
2
2
1 2
L
L
11.854
11.854
a
a
1.607
p cos m cos
5.901
x 2.5 x cos 20o
Dedendum :
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Machine Design II
Clearance:
New Pressure angle when the centre distance C is increased by 1.5% is given by:
= cos-1( r1 cos20o / r1 1.015) = 22.21o
rb
cos
inv tan
t
t 2 r ( 1 inv inv )
2r
1
Fig 4.2 Involutometry
The terminologies used in the problem are explained in earlier chapters. Hence the figures
referred are self explanatory.
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Machine Design II
Fig. 4.3 Layout for tooth thickness determination at any point on tooth profile
Solution:
r1 = 0.5.m.Z1 = 0.5 x 12 x 21=126 mm
rb = r1.Cos = 126 x cos 20o = 118.4 mm
a = 1m = 1 x 12 = 12 mm
ra = r1 + a = 126 + 12 = 138 mm
p1 = .m = . 12 = 37.14 mm
t1 = 0.5 p1 = 0.5 x 37.14 = 18.57 mm
inv = tan - = tan 0.349 0.349 = 0.015 rad
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Machine Design II
At the base circle b= 0, Hence tooth thickness tb at the base circle is:
t
t 2 r ( 1 inv inv )
b
b 2r
b
1
18.57
2 x 118.4 x(
0.015 0 ) 21.0 mm
2 x126
18.57
t 2 x 138 x
0.015 0.059 8. 20 mm
a
2 x 126
From the above, we know that, ta > tamin, hence the tip thickness is adequate and
permissible.
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