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Gear Guide2
Gear Guide2
Gear Guide2
Information on
Gears
This chapter provides fundamental theoretical and practical information about gearing. It also introduces various gear-related
standards as an aid for the designer who is going to use gears for his planning.
Table of Contents
Practical Information on Gears
Fig.1.4 Recommended
magnitude of
semitopping
Fig. 1.2 Crowning and end relief
Practical Information on Gears
2 GEAR TRAINS (1) Relationship Among the Gears in a Planetary Gear System
In order to determine the relationship among the numbers of
teeth of the sun gear A (z a), the planet gears B (z b) and the
2.1 Planetary Gear System
internal gear C (z c) and the number of planet gears (N) in
The basic form of a planetary gear system is shown in Figure the system, the parameters must satisfy the following three
2.1. It consists of a sun gear A, planet gears B, internal gear C conditions:
and carrier D.
Internal gear C
Condition No.1: zc = za + 2 zb (2.1)
zc = 48
This is the condition necessary for the center distances of
Carrier D the gears to match. Since the equation is true only for the
standard gear system, it is possible to vary the numbers of
teeth by using profile shifted gear designs.
za + zc
Condition No.2:
N
= Integer (2.3)
zb m za m zb m dab
B B B B
B A B
A A
a1 a2
a1
C
C C
zc m Condition No.2 of planetary Condition No.3 of planetary
gear system gear system
Condition No.1 of planetary
gear system Fig.2.2 Conditions for selecting gears
Practical Information on Gears
180
Condition No.3 zb +2 < (za +zb) sin (2.5)
N za zc
1+ zc za +1
Satisfying this condition insures that adjacent planet Transmission ratio = za = (2.7)
1
gears can operate without interfering with each other. zc
This is the condition that must be met for standard gear
design with equal placement of planet gears. For other Note that the direction of rotation of input and output axes
conditions, the system must satisfy the relationship: are the same. Example: za = 16, zb = 16, zc = 48,
dab< 2a1 sin (2.6) then transmission ratio = 4.
Where:
dab : tip diameter of the planet gears (b) Solar Type
a1 : center distance between the sun and
In this type, the sun gear is fixed. The internal gear C is the
planet gears input, and carrier D axis is the output. The speed ratio is
Besides the above three basic conditions, there can be calculated as in Table 2.2.
an interference problem between the internal gear C and
the planet gears B. See Section 4.2 Internal Gears (Page Table 2.2 Equations of transmission ratio for a solar type
394). Sun gearA Planet gearB Internal gearC
No. Description Carrier D
za zb zc
(2) Transmission Radio of Planetary Gear System Rotate sun gear z z
In a planetary gear system, the transmission ratio and the 1 a once while +1 - za - za 0
holding carrier b c
z za
C(Fixed) - z -1
a
zc +1
C C Transmission ratio = c
= (2.8)
-1 1
B B B
D(Fixed)
D D
Note that the directions of rotation of input and output axes
A A(Fixed) A are the same.
Example: za =16, zb =16, zc = 48,
then the transmission ratio = 1.3333333
(a) Planetary type (b) Solar type (c) Star type
Practical Information on Gears
x2 1.00 0.60 0.40 0.30 0.20 0.11 0.06 0.01 the heavy line (belt) does
b 61.0605 46.0324 37.4155 32.4521 28.2019 24.5356 22.3755 20.3854 not divide evenly by pitch.
Equation (2.11) defines this
a 0.971 1.354 1.775 2.227 2.666 3.099 3.557 4.010
condition. z3
1.105 1.512 1.726 1.835 1.933 2.014 2.053 2.088
Fig.2.5 Constrained gear system
All combinations above will not cause involute interference or
trochoid interference, but trimming interference is still there.
In order to assemble successfully, the external gear should be
assembled by inserting in the axial direction. A profile shifted z1 1 z2 (180 + 1 + 2) z3 2
+ + = integer (2.11)
internal gear and external gear, in which the difference of 180 180 180
numbers of teeth is small, belong to the field of hypocyclic
mechanism, which can produce a large reduction ratio in single
step, such as 1/100. Figure 2.6 shows a
constrained gear system 1
z1 1 za (180 + 1)
180 + 180 + am = integer (2.12)
a
Practical Information on Gears
3 TOOTH THICKNESS s
ha
Chordal tooth thickness measurement
Span measurement
Over pin or ball measurement
3.1 Chordal Tooth Thickness Measurement
d
This method employs a tooth caliper that is referenced from
the gear's tip diameter. Thickness is measured at the reference
circle. See Figure 3.1.
(1) Spur Gears
Table 3.1 presents equations for each chordal tooth thickness Fig.3.1 Chordal tooth thickness method
measurement.
Table 3.1 Equations for spur gear chordal tooth thickness
No. Item Symbol Formula Exmple
m =10
1 Tooth thickness s + 2x tan m
2 =20
z =12
90 360x tan x = + 0.3
2 Tooth thickness half angle +
z z ha =13.000
s =17.8918
3 Chordal tooth thickness s z m sin
= 8.54270
zm s =17.8256
4 Chordal height ha (1 - cos ) + ha
2 ha =13.6657
Practical Information on Gears
Table 3.4 Equations for chordal tooth thickness of helical gears in the transverse system
No. Item Symbol Formula Example
mt =4
1 Normal tooth thickness sn + 2xt tan t mt cos
2 t = 20
= 22 30' 00''
Numer of teeth in an z
2 zv z = 20
equivalent spur gear cos3
xt = + 0.3
90 360xt tan t ha = 04.7184
3 Tooth thickness half angle v
zv
+ zv s = 06.6119
zv = 25.3620
4 Chordal tooth thickness s zv mt cos sin v
v = 04.04196
zv mt cos s = 06.6065
5 Chordal height ha (1 - cos v ) + ha
2 ha = 04.8350
NOTE: Table 3.4 equations are also for the tooth profile of a Sunderland gear.
Table 3.5 Equations for chordal tooth thickness of gleason straight bevel gears
No. Item Symbol Formula Example
Tooth thickness factor m =4
1 (Coefficient of horizontal profile K Obtain from Figure 3.2 = 20
shift)
= 90
s1 m - s2 z1 = 16 z2 = 40
2 Tooth thickness z1/z2 = 0.4
m - (
s2 ha1 - ha2 )tan - Km = 00.0259
2 K
ha1 = 05.5456 ha2 = 02.4544
s 3
3 Chordal tooth thickness s s- 1 = 21.8014 2 = 68.1986
6 d2
s1 = 07.5119 s2 = 05.0545
s2 cos s1 = 07.4946 s2 = 05.0536
4 Chordal height ha ha +
4d ha1 = 05.7502 ha2 = 02.4692
Practical Information on Gears
Table 3.6 Equations for chordal tooth thickness of standard straight bevel gears
No. Item Symbol Formula Example
m m =4
1 Tooth thickness s = 20
2
= 90
Number of teeth of an z
2 zv z1 = 16 z2 = 40
equivalent spur gear cos
d1 = 64 d2 = 160
Back cone distance Rv
d ha = 04.0000
3 2 cos 1 = 21.8014 2 = 68.1986
90
s = 06.2832
4 Tooth thickness half angle v zv1 = 17.2325 zv2 = 107.7033
zv
Rv1 = 34.4650 Rv2 = 215.4066
5 Chordal tooth thickness s zv m sin v v1 = 25.2227 v2 = 00.83563
s1 = 06.2745 s2 = 06.2830
6 Chordal height ha ha +R (1 - cos v) = 04.1431
ha1 ha2 = 04.0229
180 s
Tooth angle ( ) = + hf tan (3.1)
R 2
Practical Information on Gears
z= 15
z= 16
z= 17
z= 20
z= 25
Over 30
Speed ratio, z1 / z2
Fig.3.3 Chart to determine the tooth thickness
factor k for gleason spiral bevel gears
Table 3.7 Equations for chordal tooth thickness of gleason spiral bevel gears
No. Item Symbol Formula Example
= 90 m=3 n = 20
1 Tooth thickness factor K Obtain from Figure 3.3 z1 = 20 z2 = 40 m = 35
ha1 = 3.4275 ha2 = 1.6725
s1 p - s2
K = 0.060
2 Tooth thickness p p = 9.4248
s2 - ( ha1 - ha2 ) tan n - Km
2 cos m s1 = 5.6722 s2 = 3.7526
10
Practical Information on Gears
Table 3.8 Equations for chordal tooth thickness of axial module worm gear pair
No. Item Symbol Formula Example
Axial tooth thickness of worm mt
st1 2
1 mt =3
Transverse tooth thickness of
st2 + 2x t2 tan t mt n = 20
worm wheel 2 z1 =2 z2 = 30
No. of teeth in an equivalent d1 = 38 d2 = 90
z2
2 spur gear zv2 a = 65
cos 3
(Worm wheel) xt2 = + 0.33333
Tooth thickness half angle 90 360 xt2 tan t ha1 = 03.0000 ha2 = 04.0000
3
(Worm wheel)
v2 zv2 + zv2 = 08.97263
t = 20.22780
s1 st1 cos
4 Chordal tooth thickness st1 = 04.71239 st2 = 05.44934
s2 zv mt cos sin v2 zv2 = 31.12885
(st1 sin cos ) 2 v2 = 03.34335
ha1 ha1 + s1 = 04.6547 s2 = 05.3796
4d1
5 Chordal height ha1 = 03.0035 ha2 = 04.0785
zv mt cos
ha2 ha2 + (1 - cos v2)
2
Table 3.9 Equations for chordal tooth thickness of normal module worm gear pair
No. Item Symbol Formula Example
11
Practical Information on Gears
NOTE:
1
K ( f ) = {sec (1+2f ) 2 - cos2 -inv -2f tan } (3.2)
x
where f = W
z
NOTE:
1 sin2
K ( f , ) = 1 + (cos2 + tan2 n ) (sec + 2 f )2 - 1 - inv t - 2 f tan n (3.3)
cos + tan2 n
2
xn
where f =
z
12
Practical Information on Gears
Table 3.12 Equations for span measurement of the transverse system helical gears
No. Item Symbol Formula Example
mt =3, t = 20, z = 24
kth = z K ( f , ) + 0.5 See NOTE = 22 30' 00''
1 Span number of teeth k
Select the nearest natural number of zmth as zm xt = + 0.4
n = 18.58597
mt cos cos n { (k - 0.5) + kth = 04.31728
2 Span mesurement over k teeth W k = 04
z inv t } + 2 xt mt sin n
W = 30.5910
NOTE:
sin2
K ( f , ) = 1 1 + (cos2 + tan2 n (sec + 2 f )2 - 1 -inv t -2 f tan n
(3.4)
cos + tan2 n
2
xt
where f = z cos
b b
There is a requirement of a minimum facewidth to make a
helical gear span measurement. Let bmin be the minimum value
for facewidth. See Fig.3.5.
Then bmin = W sin b + b (3.5)
W
where b is the helix angle at the base cylinder,
b = tan-1 (tan cos t )
(3.6)
= sin-1 (sin cos n)
3.3 Measurement Over Rollers(or generally called over Fig.3.5 Facewidth of helical gear
pin/ball measurement)
Internal gears are similarly measured, except that the
As shown in Figure 3.6, measurement is made over the outside measurement is between the pins. See Figure 3.9. Helical
of two pins that are inserted in diametrically opposite tooth gears can only be measured with balls. In the case of a worm,
spaces, for even tooth number gears, and as close as possible three pins are used, as shown in Figure 3.10. This is similar to
for odd tooth number gears. The procedure for measuring a the procedure of measuring a screw thread.
rack with a pin or a ball is as shown in Figure 3.8 by putting pin
or ball in the tooth space and using a micrometer between it and
a reference surface.
dp dp
M
M
d0
13
Practical Information on Gears
dp
The ideal diameters of pins when calculated from the equations inv
of Table 3.13 may not be practical. So, in practice, we select a '
tan
db
standard pin diameter close to the ideal value. After the actual d
' m
2x
diameter of pin dp is determined, the over pin measurement M inv
d+
Table 3.14 Equations for over pins measurement for spur gears
No. Item Symbol Formula Example
1 Pin diameter dp NOTE 1
dp 2 x tan
2 Involute function inv - + inv +
z mcos 2z z
dp = 1.7
3 Pressure angle at pin center Find from involute function table inv = 0.0268197
z m cos = 24.1350
Even teeth + dp
cos M = 22.2941
4 Measurement over pin (ball) M
z m cos 90
Odd teeth cos z + dp
cos
NOTE: The value of the ideal pin diameter from Table 3.13, or its approximate value, is applied as the actual diameter of pin dp here.
14
Practical Information on Gears
Table 3.15 The size of pin which has the tangent point at
d + 2xm circle of spur gears m = 1 , = 20
Number of Profile shift coefficient, x
teeth z - 0.4 - 0.2 0 0.2 0.4 0.6 0.8 1.0
010 1.6348 1.7886 1.9979 2.2687 2.6079 3.0248 3.5315
020 1.6231 1.6599 1.7245 1.8149 1.9306 2.0718 2.2389 2.4329
030 1.6418 1.6649 1.7057 1.7632 1.8369 1.9267 2.0324 2.1542
040 1.6500 1.6669 1.6967 1.7389 1.7930 1.8589 1.9365 2.0257
050 1.6547 1.6680 1.6915 1.7248 1.7675 1.8196 1.8810 1.9516
m dp
(2) Spur Racks and Helical Racks s
flank at the pitch line. The equations in Table 3.16 can, thus, be
derived. In the case of a helical rack, module m, and pressure
angle a , in Table 3.16, can be substituted by normal module mn
M
15
Practical Information on Gears
db
'
proper pin which has its tangent point at d + 2xm circle. The
2x d
equations are in Table 3.17 for obtaining the ideal pin diameter.
inv
m
The equations for calculating the between pin measurement, M,
d+
are given in Table 3.18.
M
Fig. 3.9 Between pin dimension of internal gears
Table 3.17 Equations for calculating pin diameter for internal gears
No. Item Symbol Formula Example
16
Practical Information on Gears
Table 3.19 lists ideal pin diameters for standard and profile
shifted gears under the condition of module m = 1 and pressure
angle a = 20, which makes the pin tangent to the reference
circle d + 2xm.
Table 3.19 The size of pin that is tangent at reference circle d + 2xm of internal gears m = 1 , = 20
Number
of teeth
Profile shift coefficient, x
z - 0.4 - 0.2 0 0.2 0.4 0.6 0.8 1.0
010 - 1.4789 1.5936 1.6758 1.7283 1.7519 1.7460 1.7092
020 1.4687 1.5604 1.6284 1.6759 1.7047 1.7154 1.7084 1.6837
030 1.5309 1.5942 1.6418 1.6751 1.6949 1.7016 1.6956 1.6771
040 1.5640 1.6123 1.6489 1.6745 1.6895 1.6944 1.6893 1.6744
050 1.5845 1.6236 1.6533 1.6740 1.6862 1.6900 1.6856 1.6732
Table 3.20 Equations for calculating pin diameter for helical gears in the normal system
No. Item Symbol Formula Example
Number of teeth of an z
1 zv cos3 mn = 1
equivalent spur gear
n = 20
2 xn tan n z = 20
2 Spacewidth half angle v - inv n - zv
2zv = 15 00' 00''
Pressure angle at the point pin z cos n xn = + 0.4
3 'v cos-1 v zv = 22.19211
is tangent to tooth surface z v+ 2 x n
v = 00.0427566
4 Pressure angle at pin center v tan 'v + v 'v = 24.90647
v = 00.507078
d'p = 01.9020
5 Ideal pin diameter d'p zv mn cos n (inv v + v)
17
Practical Information on Gears
Table 3.21 Equations for calculating over pins measurement for helical gears in the normal system
No. Item Symbol Formula Example
1 Pin (ball) diameter dp See NOTE
dp 2 xn tan n
-
2z + inv t +
2 Involute function inv mn z cos n Let dp = 2, then
z
t = 20.646896
3 Pressure angle at pin center Find from involute function table
inv = 00.058890
zmn cos t = 30.8534
Even Teeth + dp
cos cos
4 Measurement over pin (ball) M M = 24.5696
zmn cos t 90
Odd Teeth
cos cos
cos
z
+ dp
NOTE: The ideal pin diameter of Table 3.20, or its approximate value, is entered as the actual diameter of dp.
Table 3.22 and Table 3.23 present equations for calculating pin
measurements for helical gers in the transverse (perpendicular
to axis) system.
Table 3.22 Equations for calculating pin diameter for helical gears in the transverse system
No. Item Symbol Formula Example
Number of teeth of an z
1 zv mt = 3
equivalent spur gear cos3
t = 20
z = 36
2 Spacewidth half angle v
2 zv
- inv n - 2 xt tan t = 33 33' 26.3''
zv
n = 16.87300
3
Pressure angle at the point pin
'v cos -1 z cosx
v n xt = + 0.2
z + 2 cos
t
is tangent to tooth surface v zv = 62.20800
v = 00.014091
'v = 18.26390
4 Pressure angle at pin center v tan 'v + v v = 00.34411
inv v = 00.014258
5 Ideal pin diameter d'p zv mt cos cos n (inv v + v) d'p = 04.2190
Table 3.23 Equations for calculating over pins measurement for helical gears in the transverse system
No. Item Symbol Formula Example
1 Pin (ball) diameter dp See NOTE
dp 2 x tan
2 Involute function inv -
mt z cos cos n 2 z
+ inv t + t z t
dp =0 4.5
3 Pressure angle at pin center Find from involute function table inv = 0 0.027564
zmt cos t =024.3453
Even teeth
cos
+ dp M = 115.892
4 Measurement over pin (ball) M
zmt cos t 90
Oddteeth cos
z
+ dp
cos
NOTE: The ideal pin diameter of Table 3.22, or its approximate value is applied as the actual diameter of pin dp here.
18
Practical Information on Gears
The teeth profile of type III worms which are most popular are
cut by standard cutters with a pressure angle n = 20. This
results in the normal pressure angle of the worm being a bit
smaller than 20. The equation below shows how to calculate a
dp
type III worm in an AGMA system.
n = 0 - 90 r sin3 (3.7)
z1 r0 cos2 + r
where r : Worm reference radius
M
d
r0 : Cutter radius
z1 : Number of threads
: Lead angle of worm
The exact equation for a three wire method of type III worm
is not only difficult to comprehend, but also hard to calculate
precisely. We will introduce two approximate calculation Fig.3.10 Three wire method of a worm
methods here:
(a) Regard the tooth profile of the worm as a straight
tooth profile of a rack and apply its equations.
Using this system, the three wire method of a worm can be
calculated by Table 3.24.
Table 3.24 Equations for three wire method of worm measurement, (a)-1
No. Item Symbol Formula Example
mx =2 n = 20
mx z1 =1
1 Ideal pin diameter d'p 2 cos x d1 = 31
= 03.691386
x = 20.03827
mx 1 d'p = 03.3440
2 Three wire measuremnt M d1 - 2 tan + dp 1 + sin dp Let dp be 03.3
x x
M = 35.3173
Table 3.25 Equations for three wire method of worm measurement, (a)-2
No. Item Symbol Formula Example
mn
1 Ideal pin diameter d'p mx =2 n = 20
2 cos n
z1 =1 d1 = 31
= 03.691386
mn 1 mn = 01.99585
d1 -
2 tan n
+ dp 1 + d'p = 03.3363
sin n
2 Three wire measurement M dp Let dp be 03.3
2
- (dp cos n sin ) M = 35.3344
2 d1
19
Practical Information on Gears
Table 3.26 Equation for calculating pin diameter for worms in the axial system
No. Item Symbol Formula Example
Number of teeth of an z1 mx =2
1 zv cos3 (90 - )
equivalent spur gear n = 20
z1 =1
Spacewidth half angle v - inv d1
2 n = 31
2 zv
= 3.691386
Pressure angle at the point pin zv cos n zv
3 'v cos-1 = 3747.1491
is tangent to tooth surface zv v = 0.014485
'v = 20
4 Pressure angle at pin center v tan 'v + v v = 0.349485
inv v = 0.014960
5 Ideal pin diameter d'p zvmx cos cos n (inv v + v ) d'p = 3.3382
Table 3.27 Equation for three wire method for worms in the axial system
No. Item Symbol Formula Example
1 Pin (ball) diameter dp See NOTE 1
dp = 3.3
dp = 76.96878
-
2z1 + inv t
2 Involute function inv t
mx z1 cos cos n
inv = 04.257549
3 Prssure angle at pin center Find from involute function table inv = 04.446297
= 80.2959
z1mx cos t M
4 Three wire measurement M
tan cos
+ dp = 35.3345
NOTE 1. The value of ideal pin diameter from Table 3.26, or its approximate value, is to be used as the actual pin diameter, dp.
tan n
NOTE 2. t = tan-1
sin
20
Practical Information on Gears
Table 3.28 Equation for calculating pin diameter for worms in the normal system
No. Item Symbol Formula Example
Number of teeth of an z1 mn = 2.5
1 zv cos3 (90 - )
equivalent spur gear n = 20
z1 =1
2 Spacewidth half angle v - inv n
2zv d1 = 37
= 3.874288
Pressure angle at the point pin z cos n
3 'v cos -1 v zv = 3241.792
is tangent to tooth surface zv
v = - 0.014420
'v = 20
4 Pressure angle at pin center v tan 'v + v
v = 0.349550
inv v = 0.0149687
5 Ideal pin diameter d'p zv mn cos n (inv v + v) d'p = 4.1785
Table 3.29 Equations for three wire method for worms in the normal system
No. Item Symbol Formula Example
1 Pin (ball) diameter dp See NOTE 1.
dp = 4.2
dp t = 79.48331
2 Involute function inv
mn z1 cos n
-
2z1
+ inv t
inv t = 03.999514
3 Pressure angle at pin center Find from involute function table inv = 04.216536
= 79.8947
z1mn cos t M = 42.6897
4 Three wire measurement M
sin cos
+ dp
NOTE 1. The value of ideal pin diameter from Table 3.28, or its approximate value, is to be used as the actual pin diameter, dp.
tan n
NOTE 2. t = tan-1
sin
21
Practical Information on Gears
4 BACKLASH
jt
2
Backlash is the amount by which a tooth space exceeds the
jn
thickness of a gear tooth engaged in mesh. The general purpose 2
of backlash is to prevent gears from jamming by making
contact on both sides of their teeth simultaneously. j
there are several kinds of backlash: circumferential backlash jt , jr
normal backlash jn , radial backlash jr and angular backlash jq (),
see Figure 4.1.
jn
Table 4.1 reveals relationships among circumferential backlash jt
jt , normal backlash jn and radiall backlash jr .
jtt
2 Helical gear jnn = jtt cos n cos jr =
2 tan t
jt
3 Straight bevel gear jn = jt cos jr =
2 tan sin
jtt
4 Spiral bevel gear jnn = jtt cos n cos m jr =
2 tan t sin
Worm jnn = jtt1 cos n sin jtt2
5 jr =
Worm wheel jnn = jtt2 cos n cos 2 tan x
360
j = jt ( degrees ) (4.1)
d
From Figure 4.1 we can derive backlash of spur gear mesh as:
jn = jt cos
jt (4.2)
jr = 2tan
22
Practical Information on Gears
(2) Backlash of Helical Gear Mesh (3) Backlash of Straight Bevel Gear Mesh
The helical gear has two kinds of backlash when referring to the Figure 4.3 expresses backlash for a straight bevel gear mesh.
tooth space. There is a cross section in the normal direction of
the tooth surface(n), and a cross section in the radial direction
perpendicular to the axis,(t)
jnn = backlash in the direction normal to the tooth surface jt
2
jtn = backlash in the circular direction in the cross section jn
normal to the tooth 2
jnt = backlash in the direction normal to the tooth surface jt
2tan
in the cross section perpendicular to the axis jr1
jtt = backlash in the circular direction perpendicular to the axis 1
j r'
jr2
jtn
jtt
Fig. 4.3 Backlash of straight bevel gear mesh
23
Practical Information on Gears
(4) Backlash of a Spiral Bevel Gear Mesh (5) Backlash of Worm Gear Pair Mesh
Figure 4.5 expresses backlash for a worm gear pair mesh.
Figure 4.4 delineates backlash for a spiral bevel gear mesh.
t
jtn m
jtt2 2 jr
n jtn
jnt1
jtt jtn jnn
jtt jtt1
jtt1
2
jnt
2
t
jtt jtt2
jr1 2tan
1 x
jnt2
j r' 2 jr
jr2
Fig.4.5 Backlash of worm gear pair
24
Practical Information on Gears
4.2 Tooth Thickness and Backlash 4.3 Gear Train and Backlash
There are two ways to produce backlash. One is to enlarge the The discussions so far involved a single pair of gears. Now, we
center distance. The other is to reduce the tooth thickness. The are going to discuss two stage gear trains and their backlash. In
latter is much more popular than the former. We are going to a two stage gear train, as Figure 4.6 shows, jt1 and jt4 represent
discuss more about the way of reducing the tooth thickness. the backlashes of first stage gear train and second stage gear
train respectively.
In SECTION 3, we have discussed the standard tooth thickness
s1 and s2. In the meshing of a pair of gears, if the tooth thickness
of pinion and gear were reduced by s1 and s2, they would
produce a backlash of s1 and s2 in the direction of the pitch
circle. Let the magnitude of s1 and s2 be 0.1. We know that
= 20 , then:
jt = s1 + s2
= 0.1+ 0.1 = 0.2 Gear 4 Gear 3 Gear 2 Gear 1
We can convert it into the backlash on normal direction jn: ( z 4 ,d 4 ) ( z 3 ,d 3 ) ( z 2 ,d 2 ) ( z 1 ,d 1 )
jn = jt cos
= 0.2 cos 20 = 0.1879
25
Practical Information on Gears
This involves adjustment of either the gear's effective tooth Center distance adjustment of backlash can be accomplished in
thickness or the mesh center distance. These two independent two ways:
adjustments can be used to produce four possible combinations
as shown in Table 4.2.
j Linear Movement
Figure 4.8jshows adjustment along the line-of-centers in a
straight or parallel axes manner. After setting to the desired
value of backlash, the centers are locked in place.
Table 4.2 The combination of adjustment
Center Distance
k Rotary Movement
Fixed Adjustable Figure 4.8 kshows an alternate way of achieving center
Gear Fixed A C distance adjustment by rotation of one of the gear centers by
Size Adjustable B D means of a swing arm on an eccentric bushing. Again, once
the desired backlash setting is found, the positioning arm is
locked.
(A) Case A
By design, center distance and tooth thickness are such that they
yield the proper amount of desired minimum backlash. Center
distance and tooth thickness size are fixed at correct values and
require precision manufacturing.
(B) Case B
26
Practical Information on Gears
Dynamic methods relate to the static techniques. However, A duplex lead worm gear mesh is a special design in which
they involve a forced adjustment of either the effective tooth backlash can be adjusted by shifting the worm axially. It is
thickness or the center distance. useful for worm drives in high precision turntables and hobbing
machines. Figure 4.9 presents the basic concept of a duplex
lead worm gear pair.
(A) Backlash Removal by Forced Tooth Contact
This is derived from static Case B. Referring to Figure 4.7j, a pR pR pR pR
forcing spring rotates the two gear halves apart. This results in
an effective tooth thickness that continually fills the entire tooth Left side Right side
space in all mesh positions.
27
Practical Information on Gears
5 GEAR ACCURACY
Gears are one of the basic elements used to transmit power and position. As designers, we desire them to meet various demands:
jMaximum power capability
kMinimum size.
lMinimum noise (silent operation).
mAccurate rotation/position
To meet various levels of these demands requires appropriate
degrees of gear accuracy. This involves several gear features.
Total Cumulative Pitch Deviation (Fp )
5.1 Accuracy of Spur and Helical Gears Difference between theoretical summation over any number of
teeth interval, and summation of actual pitch measurement over
JIS B 1702-01: 1998 and JIS B 1702-02: 1998 prescribe gear the same interval.
accuracy on spur and helical gears. These two revises the
k pt
previous specification JIS B 1702: 1976. which described 9 +F
grades grouped from 0 through 8. In order to avoid confusion pk
Indicator reding
15 Single pitch deviation
JIS B 1702-2:1998 Cylindrical gears - gear accuracy - Part 2: Total cumulative pitch
deviationerror
Definitions and allowable values of deviations relevant to
Deviation (unit:mm)
10
radial composite deviations and runout information. (This
specification consists of 9 grades of gear accuracy grouped 5 Max.Accumulated
from 4 through 12, - 4, the highest grade and 12, the lowest Max. Single
grade ). 0
-6
Single Pitch Deviation ( fpt )
The deviation between actual measured pitch value between
- 10
any adjacent tooth surface and theoretical circular pitch. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1
Tooth position number
Fig.5.3 Examples of pitch deviation for a 15 tooth gear
Addendum Dedendum
A E F
L :Evaluation range
F
fi' Max.value
Fi''
+
L : Evaluation range
b : Facewidth
360/z
F
- 0 360
Fig.5.7 Chart of total radial composite deviation
L
b
Runout Error of Gear Teeth (Fr )
Design helix
Most often runout error is mesured by indicating the position
Actual helix
of a pin or ball inserted in each tooth space around the gear
Fig.5.5 Total helix deviation (F ) and taking the largest difference.
Runout causes a number of problems, one of which is
noise. The source of this error is most often insufficient
accuracy and ruggedness of the cutting arbor and tooling
system. And, therefore, it is very importnt to pay attention
to these cutting arbor and tooling system to reduce runout
error. Shown in Fig.5.8 is the chart of runout. The values of
runout includes eccentricity.
Eccentricity
Fr
29
Practical Information on Gears
30
Practical Information on Gears
5.3 Running (Dynamic) Gear Testing Table 5.3 Allowable values of running errors, ( m)
Grade Tooth-to-tooth composite error Total composite error
An alternate simple means of testing the general accuracy of a 1.12m + 3.55
Extra fine (0) ( ( 1.4W + 4.0) + 0.5 ( 1.12m + 3.55)
gear is to rotate it with a mate, preferably of known high quality, 1 01.6m + 5.00 ((12.0W + 05.6) + 0.5 ((1.6 m + 05.0)
and measure characteristics during rotation. This kind of tester 2 2.24m + 7.10 ((12.8W + 08.0) + 0.5 ((2.24m + 07.1)
can be either single contact (fixed center distance method) or 3 3.15m + 10.0 ((14.0W + 11.2) + 0.5 ((3.15m + 10.0)
dual (variable center distance method). This refers to action on
4 04.5m + 14.0 ((15.6W + 16.0) + 0.5 ((04.5m + 14.0)
one side or simultaneously on both sides of the tooth. This is
5 06.3m + 20.0 ((18.0W + 22.4) + 0.5 ((06.3m + 20.0)
also commonly referred to as single and double flank testing.
6 09.0m + 28.0 ((11.2W + 31.5) + 0.5 ((09.0m + 28.0)
Because of simplicity, dual contact testing is more popular than
7 12.5m + 40.0 ((22.4W + 63.0) + 0.5 ((12.5m + 40.0)
single contact.
8 18.0m + 56.0 ( 45.0W + 125.0) + 0.5 ((18.0m + 56.0)
31
Practical Information on Gears
Tooth contact is critical to noise, vibration, efficiency, strength, It is important to check the tooth contact of a bevel gear both
wear and life. To obtain good contact, the designer must give during manufacturing and again in final assembly. The method is
proper consideration to the following features: to apply a colored dye and observe the contact area after running.
Usually some load is applied, either the actual or applied braking,
Modifying the tooth shape to realize a realistic contact condition. Ideal contact favors the
Improve tooth contact by crowning or end relief. toe end under no or light load, as shown in Figure 6.1; and, as
load is increased to full load, contact shifts to the central part of
Using higher precision gear the tooth width.
Specify higher accuracy by design. Also, specify that the
manufacturing process is to include grinding or lapping.
32
Practical Information on Gears
(1) The Offset Error of Shaft Alignment The various contact patterns due to mounting distance errors
are shown in Figure 6.4.
If a gearbox has an offset error, then it will produce crossed
contact, as shown in Figure 6.2. This error often appears as (+) Error (-) Error
if error is in the gear tooth orientation.
Error
(-) Shaft
angle
error
Rotating direction
33
Practical Information on Gears
of backlash.
Fig.6.7 Poor tooth contact due to center distance error
Error
Error
Error
(2) Center Distance Error Fig.6.8 Poor tooth contact due to mounting distance error
34
Practical Information on Gears
Table 7.1- Ranges of tangential speed (m/s) for spur and bevel gears
7 LUBRICATION OF GEARS
Range of tangential speed v (m/s)
No. Lubrication
The purpose of lubricating gears is as follows:
0 5 10 15 20 25
1. Promote sliding between teeth to reduce the coefficient of
friction . 1 Grease lubrication
2. Limit the temperature rise caused by rolling and sliding 2 Splash lubrication
friction. Forced oil circultion
3 lubrication
To avoid difficulties such as tooth wear and premature failure,
the correct lubricant must be chosen. Table 7.1 Ranges of sliding speed (m/s) for worm wheels
35
Practical Information on Gears
Gear Horizontal shaft Vertical shaft (Horizontal shaft) Worm - above Worm -below
Oil level
1
3h 1h 1b d
1 d 2 1
3 2
Level 0 1h 1h 1b 1 0
3 3 4 d1
h = Tooth depth, b = Facewidth, d2 = Reference diameter of worm wheel, d1 = Reference diameter of worm
36
Practical Information on Gears
An oil film must be formed at the contact surface of the teeth to The lubricant should have the properties listed in Table 7.3.
minimize friction and to prevent dry metal-to-metal contact.
Antiscoring Lubricant should have the property to prevent the scoring failure of tooth surface
2
property while under high-pressure of load.
Oxidization A good lubricant should not oxidize easily and must perform in moist and high-
3 and heat
stability temperature environment for long duration.
Water Moisture tends to condense due to temperature change when the gears are stopped.
4 antiaffinity The lubricant should have the property of isolating moisture and water from
property lubricant
Antifoam If the lubricant foams under agitation, it will not provide a good oil film. Antifoam
5
property property is a vital requirement.
Anticorrosion Lubrication should be neutral and stable to prevent corrosion from rust that may
6
property mix into the oil.
Table 7.4 ISO viscosity grade of industrial lubricant ( JIS K 2001 ) Table 7.5 AGMA viscosity grades
Kinematic viscosity Kinematic viscosity range AGMA No.of gear oil ISO viscosity
ISO center value
10-6m2/s(cSt) R & O type EP type grades
Viscosity grade 10-6m2/s(cSt)
(40C) (40C)
1 8 Acomp 2 Ep VG 4600
ISO VG 1502 1502.2 More than 1.98 and less than 2.42 2 8 Acomp 2 EP VG 6800
ISO VG 1503 1503.2 More than 2.88 and less than 3.52 3 8 Acomp 3 EP VG 1000
ISO VG 1505 1504.6 More than 4.14 and less than 5.06 4 8 Acomp 4 EP VG 1500
ISO VG 1507 1506.8 More than 6.12 and less than 7.48 5 8 Acomp 5 EP VG 2200
ISO VG 1510 1510.0 More than 9.0 and less than 11.00 6 8 Acomp 6 EP VG 3200
ISO VG 1515 1515.0 More than 13.5 and less than 16.5 7 7 compA 7 EP VG 4600
ISO VG 1522 1522.2 More than 19.8 and less than 24.2 8 8 compA 8 EP VG 6800
ISO VG 1532 1532.2 More than 28.8 and less than 35.2 1 8 Acomp 2 Ep VG 1000
ISO VG 1546 1546.2 More than 41.4 and less than 50.6 9 8 Acomp 9 EP VG 1500
ISO VG 1568 1568.2 More than 61.2 and less than 74.8
ISO VG 1100 1100.2 More than 90.0 and less than 110
ISO VG 1150 1150.2 More than 135 and less than 165
ISO VG 1220 1220.2 More than 198 and less than 242
ISO VG 1320 1320.2 More than 288. and less than 352
ISO VG 1460 1460.2 More than 414 and less than 506.
ISO VG 1680 1680.2 More than 612. and less than 748
ISO VG 1000 1000.2 More than 900 and less than 1100.
ISO VG 1500 1500.2 More than 1350 and less than 1650
37
Practical Information on Gears
Table 7.7 is the application guide chart for worm gear pair from AGMA 250.03.
Table 7.7 Recommended lubricants for worm gear pair by AGMA
Type Center Rotating Ambient temperature, C Rotating speed Ambient temperature, C
of distance speed of worm of Worm
worm mm min-1 10 ~ 16 10 ~ 52 min-1 10 ~ 16 10 ~ 52
1 150 700 700 < 8 Comp
150 ~ 300 450 450 <
Cylindrical
300 ~ 460 300 7 Comp 8 Comp 300 < 7 Comp
type
460 ~ 600 250 250 <
600 <150 200 200 <
150 150 700 700 <
150 ~ 300 450 450 <
Enveloping
300 ~ 460 300 8 Comp 8 AComp 300 < 8 Comp
type
460 ~ 600 250 250 <
600 <150 200 200 <
Table 7.8 expresses the reference value of viscosity of lubricant used in the equations for the strength of worm gears in JGMA 405-01.
Table 7.8 Reference values of viscosity unit: cSt/37.8C
Operating temperature Sliding speed m/s
Maximum running Starting temperature Less than 2.5 2.5 through 5 More than 5
10C ~ 0C 110 ~ 130 110 ~ 130 110 ~ 130
10C ~ 10C
More than 0C 110 ~ 150 110 ~ 150 110 ~ 150
10C ~ 30C More than 0C 200 ~ 245 150 ~ 200 150 ~ 200
30C ~ 55C More than 0C 350 ~ 510 245 ~ 350 200 ~ 245
55C ~ 80C More than 0C 510 ~ 780 350 ~ 510 245 ~ 350
80C ~ 100C More than 0C 900 ~ 1100 510 ~ 780 350 ~ 510
After making decision about which grade of viscosity to select, taking into consideration the usage (for spur gear, worm gear pair etc.) and
usage conditions (dimensions of mechanical equipment, ambient temperature etc.), choose the appropriate lubricant. Technical manual of
the libricant manufacturer may be of great help.
38
Practical Information on Gears
8 GEAR FORCES
In designing a gear, it is important to analyze the magnitude Table 8.1 presents the equations for tangential (circumferential)
and direction of the forces acting upon the gear teeth, shafts, force Ft (kgf), axial (thrust) force Fx(kgf), and radial force
bearings, etc. In analyzing these forces, an idealized assumption Fr in relation to the transmission force Fn acting upon the
is made that the tooth forces are acting upon the central part of central part of the tooh flank.
the tooth flank. T and T1 shown therein represent input torque (kgfm).
Fr2 Fr2
Ft
Fn
Fr
Driven gear
'
Fig.8.1 Forces acting on a spur gear mesh Fig.8.2 Directions of forces acting on a spur gear mesh
39
Practical Information on Gears
8.2 Forces in a Helical Gear Mesh The directions of forces acting on a helical gear mesh are
The helical gear's transmission force, Fn, which is normal to the shown in Figure 8.4.
tooth surface, can be resolved into a tangential component, F1, The axial thrust sub-component from drive gear, Fx1, equals the
and a radial component, Fr, as shown in Figure 8.3. driven gear's, Fx2, but their directions are opposite.
Again, this case is the same as tangential components and radial
components.
F1 = Fn cos n
(8.2)
Fr = Fn sin n
Fx
The tangential component, F 1, can be further resolved into
Fx = Ft tan
(8.4) F1 n
tan n
Fr = Ft Fn
cos
Fig.8.3 Forces acting on a helical gear mesh
40
Practical Information on Gears
Let a pair of straight bevel gears with a shaft angle = 90 , a 8.4 Forces in A Spiral Bevel Gear Mesh
pressure angle n = 20 and tangential force, Ft , to the central
part of tooth face be 100. Axial force, Fx , and radial force, Fr, Spiral bevel gear teeth have convex and concave sides.
will be as presented in Table 8.2. Depending on which surface the force is acting on, the direction
and magnitude changes. They differ depending upon which is
Axial force Fx
the driver and which is the driven.
Table 8.2 Values
Radial force Fr
41
Practical Information on Gears
The value of axial force, Fx, of a spira bevel gear, from Table 8.4,
could become negative. At that point, there are forces tending to
push the two gears together. If there is any axial play in the
Fig.8.9 When meshing on the concave side of tooth face
bearing, it may lead to the undesirable condition of the mesh
On the surface which is normal to the tooth profile at the central having no backlash. Therefore, it is important to pay particular
portion of the tooth, the transmission force Fn can be split into attention to axial plays.
F1 and F2. See Figure 8.9:
42
Practical Information on Gears
From Table 8.4(2), we understand that axial turning point of Figure 8.10 describes the forces for a pair of spiral bevel gears
axial force, Fx, changes from positive to negative in the range of with shaft angle = 90, pressure angle n = 20, spiral angle
gear ratio from 1.5 to 2.0 when a gear carries force on the convex m = 35 and the gear ratio z2/z1, ranging from 1 to 1.57357.
suide. The precise turning point of axial force, Fx, is at the gear Figure 8.11 expresses the forces of another pair of spiral bevel
ratio z2/z1 =1.57357. gears taken with the gear ratio z 2/z 1 equal to or larger than
1.57357.
Driver
Driver
Fr1 Fr1
Fx1 Fx1
Fr2 Fr1 Fr2 Fr1
Ft2 Ft1 Ft2 Ft1
Fx2 Fx2
Driver Driver
Fr1
Fr1
Ft1 Fx1 Ft2 Ft1 Ft2
Fx1
Fr1 Fr1
Fr2 Fr2
8.5 Forces in a Worm Gear Pair Mesh At the pitch surface of the worm, there is, in addition to the
(1) Worm as the Driver n tangential component, F1, a friction sliding force on the tooth
F1 surface, Fn . These two forces can be resolved into the circular
For the case of a worm as
and axial directions as:
the driver, Figure 8.12, the Fn
transmission force, Fn, which
Fr1 Ft1 = F1 sin + Fn cos
is normal to the tooth surface at (8.18)
the pitch circle can be resolved Fx1 = F1 cos Fn sin
into components F1 and Fr1. and by substitution, the result is:
Ft1
Fn F1
F1 = Fn cos n Ft1 = Fn (cos n sin + cos )
Fx1
Fx1 = Fn (cos n cos sin )
Fr1 = Fn sin n (8.19)
(8.17) Fr1 = Fn sin n
Figure 8.13 presents the direction of forces in a worm gear In a worm gear pair mesh with a shaft angle = 90 , the axial
pair mesh with a shaft angle = 90 . These forces relate as force acting on drive gear Fx1 equals the tangential force acting
follows: on driven gear Ft2. Similarly, the tangential force acting on
Fx1 = Ft2
drive gear Ft1 equals the axial force acting on driven gear Fx2.
The radial force Fr1 equals that of Fr2.
Ft1 = Fx2 (8.20)
The equations concerning worm and worm wheel forces
Fr1 = Fr2 contain the coefficient . The coefficient of friction has a great
effect on the transmission of a worm gear pair. Equation (8-21)
presents the efficiency when the worm is the driver.
R = T2 = Ft2 tan
T 1i Ft1
cos n cos sin (8.21)
= cos sin + cos tan
n
T1 i Ft1
I = = Fig.8.14 Forces in a worm gear pair mesh
T2 Ft2 tan
cos sin cos 1 (8.23)
= cos n cos + sin
n tan
44
Practical Information on Gears
In the general case when the shaft angle is not 90 , as in Figure I Fx1 I
8.15, the driver screw gear has the same forces as for a worm
1
mesh. These are expressed in Equations (8.24).
2
Ft1 = Fn (cos n cos 1 + sin 1)
Ft1
Fx1 = Fn (cos n sin 1 cos 1) (8.24)
II
Fr1 = Fn sin n
Fig.8.15 The forces in a screw gear mesh
Forces acting on the driven gear can be calculated per Equations
(8.25).
Driver Driver
45
Practical Information on Gears
db2
d'2
2
da
'
Spur gear j
da1 db1 da2 db2 + a sin '
2 2 2 2
3 2 2 2 2
Internal gear k m cos
46
Practical Information on Gears
Table 9.3 Equations for transverse contact ratio of nonparallel and nonintersecting meshes,
No. Type of gear mesh Equation of transverse contact ratio,
47
Practical Information on Gears
NOTE: The module m in spiral bevel gear equation is the transverse module.
b
px
pn
48
Practical Information on Gears
10 GEAR NOISE
49
Practical Information on Gears
j Count up how many teeth a sample spur gear has. z = Table : Base pitch pb
k Measure its tip diameter. da = Pressure angle Pressure angle
Module Module
l Estimate a rough approxmation of its module assuming 20 14.5 20 14.5
that it has unshifted standard full depth tooth, using the
equation: 1.00 02.952 03.042 08 23.619 24.332
da
m= m .=. 1.25 03.690 03.802 09 26.569 27.373
z+2
Measure the span measurement of k, span number of 1.50 04.428 04.562 10 29.521 30.415
teeth. Also, measure the same of k 1. Then calculate the
2.00 05.904 06.083 11 32.473 33.456
difference.
Span number of teeth k = Span measurement Wk = 2.50 07.380 07.604 12 35.425 36.498
" k 1= Wk 1 = 3.00 08.856 09.125 14 41.329 42.581
The difference = 3.50 10.332 10.645 16 47.234 48.664
This difference represents pb = m cos .
Select module m and pressure angle from the table on 4.00 11.808 12.166 18 53.138 54.747
the right. 5.00 14.760 15.208 20 59.042 60.830
m=
6.00 17.712 18.249 22 64.946 66.913
=
7.00 20.664 21.291 25 73.802 76.037
Calculate the profile shift coefficient x based on the above
m and pressure angle and span measurement W. NOTE: This table deals with pressure angle 20 and 14.5 only. There may
x= be the case where the degree of pressure angle is different.
pz = zmn
sin
Measuring helix angle on tooth tips
Given the lead pz, number of teeth z normal module m n, the
helix angle can be found with the equation:
zm
= sin-1 p n
z
The number of teeth z and normal module mn can be obtained
using the method explained in 11 above. In order to obtain pz,
determine da by measuring tip diameter. Then prepare a piece
of paper. Put ink on the outside edge of a helical gear, roll it on
the paper pressing it tightly. With the protractor measure angle
of the mark printed on the paper, k.
pz = da
tan k
50