12/11/2019

GEARS
Elias Attallah
Contents

INTRODUCTION ........................................................................................................................................ 1
Chapter 1 ....................................................................................................................................................... 2
Gear ............................................................................................................................................................... 2
1.1 What is a gear? .................................................................................................................................... 2
1.2 Dimensions of a Gear.......................................................................................................................... 3
1.3 Gear Drives ......................................................................................................................................... 3
Chapter 2 ....................................................................................................................................................... 7
Gear Types .................................................................................................................................................... 7
2.1 Spur Gears........................................................................................................................................... 7
2.2 Helical Gears....................................................................................................................................... 8
2.3 Double Helical and Harringbone Gears: ............................................................................................. 8
2.3Bevel Gears: ......................................................................................................................................... 8
2.4Worm Gears: ........................................................................................................................................ 9
Chapter 3 ..................................................................................................................................................... 10
Gear Wear and Failure ................................................................................................................................ 10
Simulator Spotlight – iTeachGears ............................................................................................................. 13

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INTRODUCTION

Gear is most essential element of power transmission prefer for short distance. It is very
economical and very effective way of power transmission .it is used all engineering purpose for
power transmission. A gear is a machine element designed to transmit force and motion from one
mechanical unit to another.
Various types of gears have been developed to perform different functions, the most common of
these being spur gears, helical gears, straight and spiral bevel gears, and hypoid gears.
Many modes of gear failure have been identified, for example fatigue, impact, wear or plastic
deformation. one of the most common causes of gear failure is tooth bending fatigue.
Fatigue is the most common failure in gearing.

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 Chapter 1

Gear
1.1 What is a gear?
A toothed part that meshes with another toothed part to transmit power, change speed, or
direction.
The larger of two interacting gears is referred to as the “Gear”.
The smaller one is called the “pinion”

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1.2 Dimensions of a Gear

1.3 Gear Drives

Circular Pitch – The distance between one point on a tooth and the corresponding point on the
next tooth when measured along the pitch circle

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The pitch circle of a gear is the location on the gear where speed and torque are transmitted.
This happens at the contact point between the gear teeth along a line that passes through the line
of centers of the two gears.

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The pitch diameter is the diameter of the pitch circle and is used to calculate the speed and torque
to the driven shaft.
The pitch circle is only significant in determining the pitch diameter.

Pressure Angle: The angle at which power is passed from the tooth of one gear to the tooth of
the other.
Commonly pressure angle is 20o
Backlash: the space between the non-driving sides of the adjacent teeth of two meshing gears.
Backlash prevents gear binding and wearing.

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Root Clearance: the radial distance between the top of the tooth of the pinion and the bottom of
the tooth of the gear.

Gear ratio determines how fast the driven gear will turn.
The teeth of the driver gear transfer speed to the teeth of the driven gear such that the points on
the teeth of the two gears at their pitch diameters move at the same surface speed.
Different size gears have different RPM.

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 Chapter 2

Gear Types

1. Spur Gears
2. Helical Gears
3. Double Helical Gears
4. Herringbone Gears
5. Bevel Gears
6. Worm Gears

2.1 Spur Gears

Advantages:
1. Simple construction and installation

2. Low cost
3. Can have:
- external teeth
- internal teeth (such as planetary gears)
- teeth on a rack (rack and pinion)
Disadvantages:
1. Can generate high friction so they are only used for slow to moderate speeds.
2. As velocity increases vibration increases.

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2.2 Helical Gears
Advantages:
1. Run more quietly and smoothly than spur gears.
2. More efficient
3. Can run at higher speeds
4. Has a higher load carrying capacity than spur gears of similar size.
Disadvantages:
1. Create thrust loads, thus need to be supported by proper bearings.
2. High cost
Note : Gears on parallel shafts must be of opposite hands.

2.3 Double Helical and Harringbone Gears:

Advantages:
1. Can handle extreme loads
2. The axial thrust associated with single helical gears is cancelled
Disadvantages:
1. High cost
2. Sensitive to misalignment (can bind if not precisely aligned)

2.3 Bevel Gears:

Types: Bevel gears can be Straight, Spiral, or Hypoid. The most common is the hypoid, as
straight bevel gears generate high noises while at operation.
Advantages:
Operate on shafts intersecting at an angle, usually the angle is 90o (but not always).
Disadvantages:
1. Generally low gear ratios
2. The shaft bearings must support the load.
3. Require complex and precise installation.

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 2.4 Worm Gears:

Advantages:
1. Run very quietly and smoothly.
2. Resistant to shock loads
3. Can have very high gear ratios in a compact area.
Disadvantages:
1. Low efficiency due to the high friction resulting from a pure sliding action.
2. Worm always should only be the input and the gear should always only be the output.

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 Chapter 3
Gear Wear and Failure

Main causes:
1. Loads:
➢ continuous overloads
➢ shock loads
➢ vibratory loads
➢ Harsh operating environments such as high ambient temperatures, presence of dust and
sand contaminants.
2. Installation: improper installation and alignment.
3. Poor maintenance: improper lubrication level, type, or excess contamination.

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Fatigue

Fatigue failure results from cracking under repeated stresses much lower than the ultimate tensile
strength. This type of
failure:
• Ordinarily depends upon the number of repetitions of a given stress range rather than the total
time under load
• Does not occur below some stress amplitude called the fatigue limit
• Is greatly encouraged by notches, grooves, surface discontinuities, and subsurface imperfections
that will
decrease the stress amplitude that can be withstood for a fixed number of stress cycles
• Is increased significantly by increasing the average tensile stress of the loading cycle

There are three stages within a fatigue failure that must be studied closely: the origin of the
fracture, the progression under successive cycles of loading, and final rupture of the part when
the spreading crack has sufficiently weakened the section.
Impact

Tooth-Bending Impact. When a tooth is removed from a gear within a very few cycles (usually one or
two), the fracture is uniform in structure and does not show the striations common to the fatigue mode of
failure. They are usually random, due to a sudden shock load, either in a forward or reverse direction, and
do not necessarily originate at the root radius. In fact, if the fracture did originate at the root radius, it
would follow a rather flat path across to the opposite root radius rather than travel downward toward the
zero-stress point.
Tooth Shear. When the impact is very high and the time of contact is very short, and if the ductility of the
material will allow it, the resultant tooth failure mode will be shear. The fractured area appears to be
highly glazed, and the direction of the fracture will be from straight across the tooth to a convex shape.
For example, a loaded gear and pinion set were operating at a high rate of speed when the pinion stopped
instantaneously

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The location in the spectrum of all the gear related frequencies requires the knowledge of a minimum
amount of gearbox data. These data are the rotating speed of the input shaft or the output shaft and
the number of teeth of the different gears. In this way there will be no doubt in the identification of
the gear frequencies and their sidebands. The frequencies associated directly with a gear assembly
are as follows:
• Gearmesh frequency (GMF): is characteristic of each gear assembly and appears in the
frequency spectrum regardless of the condition of the gears. Its amplitude depends significantly
on the load at the time of reading. It is calculated according to the following formula where, Z is
the number of teeth and RPM is the rotating speed of the gear.

• Gearmesh frequency side bands: these are frequencies equidistant from the gear mesh frequency.
These sidebands correspond to the rotating frequency of the pinion and the gear. They are very
important in the diagnosis of the gear assembly, since they indicate if the gear or the pinion are
in bad condition.
• Hunting tooth frequency (HTF): to calculate it the number of assembly phases (NA) must be
calculated in advance as described in the following section. Indicates the frequency with which a
tooth of the gear engages with the same tooth of the pinion. In case of damage to one tooth of
the gear and another of the pinion, the maximum vibration will occur when both faults come into
contact.

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 This frequency is very low so it is difficult to locate in the frequency spectrum, being detected
more easily in the time waveform.
HTF=GMF×NAZP×ZGHTF=GMF×NAZP×ZG
• Assembly phase frequency (APF): indicates that as a result of wear, the space between teeth and
the teeth profile has changed.
APF=GMFNAAPF=GMFNA
• Gear natural frequencies: when some kind of gear deterioration develops the natural frequencies
of the gears can be excited.

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Simulator Spotlight – iTeachGears

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 Where :
GMF- Gear-Mesh Frequency
GAPF-Gear Assembly Phase Frequencies

GAPF= Prime factors*speed

Reference :
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[1] https://www.mobiusinstitute.com/
[2] Gears –and How Their World is Changing by Neville W. Sachs, P.E. Neville W. Sachs, P.E., PLLC,
2014
[3] Gear Fault Identification by using Vibration Analysis, Ajanalkar Sagar Shivputra and Ganesh D.
Shrigandhi
[4] Different types Failure in gears-A Review, Arvind Yadav Student of M.E., Department of Mechanical
Engineering, MITS Gwalior, (M.P.), India

[5] L.E. Alban, Systematic Analysis of Gear Failures, American Society for Metals, 1985

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