Gears

Dr. Mostafa Rostom A. Atia

Associate Prof.

1
Gear arrangement

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 Gear Ratio

Gear Ratio = Speed A / Speed B

= Number of teeth B / Number of teeth A
= Radius B / Radius A

Torque Ratio = Torque A / Torque B

= Velocity B / Velocity A
= Number of teeth A / Number of teeth B
= Radius A / Radius B

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External & Internal gear

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 Types of gears

Spur gear

Rack and pinion

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 Types of gears

Helical gear

Herringbone gear

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 Types of gears

internal gear

Spiral gear

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Types of gears

Bevel gear

Straight Bevel gear

Spiral Bevel gear Hypoid Bevel gear

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Types of gears

Worm gear

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Types of gears

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 Conjugate Action

 When the tooth profiles, or cams, are designed so as to produce a

constant angular velocity ratio during meshing, these are said to
have conjugate action.

 One of these solutions is the

involute profile, which, with few
exceptions, is in universal use for
gear teeth.

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Involute Fundamentals

Generation of an involute Involute action

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 Gear-tooth nomenclature
External Spur Gears

 Module, (m) = Pitch circle diameter / No of teeth (mm)

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Useful data

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Relations (Spur Gear)

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 Internal and rack gears

Rack and pinion gear

Internal spur gear

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Gear Parameters, Helical

mt = mn / cos ψ

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 Contact ratio, spur and helical gears

b: Gear width
φt : tangential pressure angle
ψ: Helix angle
ψ = 0 for spur gear

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Interference

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Gear Materials

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Gear Drawing

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Gear Drawing

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Gear form milling

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Gear generating

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Gear generation methods
Hobbing Machine Gear Shaper

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 Force analysis, Spur gear

Transmitted torque, T

Where: Wt is the tangential force

P = T x 2π n /60

P: Power, watt
n: speed, rpm

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Force analysis, Helical gear

mt = mn / cos ψ
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 Static bending stress on tooth
𝑘𝑘𝑣𝑣 𝑊𝑊 𝑡𝑡
σ = 𝑘𝑘𝑠𝑠 𝑘𝑘1
𝐹𝐹 𝑚𝑚𝑡𝑡 𝑌𝑌
F: Tooth width
kv: Velocity factor
ks: Service factor
k1: Lubrication factor
Y: Form factor

Where: V: Tangential Velocity m/sec M.Atia 28

k1 = 1.15
for proper lubrication ks
= 1.25
for regular lubrication

= 1.35
for inadequate lubrication

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 Dynamic load on tooth
𝑡𝑡
𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐ψ
𝑃𝑃𝑑𝑑 = 𝑊𝑊 +
0.15
1 + 𝑣𝑣 √𝑠𝑠
𝑠𝑠 = 𝑘𝑘𝑑𝑑 𝑌𝑌 𝑐𝑐𝑐𝑐𝑐𝑐 2 ψ + 𝑊𝑊 𝑡𝑡
𝑘𝑘 𝑒𝑒 Permissible error, e, mm
𝑘𝑘𝑑𝑑 =
1 1 Class of machining
�𝐸𝐸 + 𝐸𝐸 � Module
𝑝𝑝 𝑔𝑔 Commercial Accurate Precision
Up to 1.5 0.05 0.025 0.0125
k = 0.10 φ = 15° 6
7
0.06
0.07
0.030
0.035
0.0150
0.0175
= 0.11 φ = 20° 8 0.08 0.040 0.0200
= 0.115 φ = 15° stub 12 0.10 0.050 0.0250
25 0.12 0.060 0.0300

V, m/sec 1 2 5 7 10 20 30
emax, mm 0.125 0.1 0.0625 0.05 0.0375 0.025 0.0125

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 Endurance load on tooth

𝑃𝑃𝑒𝑒𝑒𝑒 = 𝑆𝑆𝑒𝑒 𝑌𝑌 𝐹𝐹 𝑚𝑚𝑡𝑡

Se = 0.75 σy / 1.5 = BHN / (4 × 1.5) For repeated load

= 0.50 σy / 1.5 = BHN / (6 × 1.5) For completely reversed load

Safety margin
Pen ≥ 1.25 Pd For Steady load
≥ 1.35 Pd For Pulsating load
≥ 1.50 Pd For Shock load

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 Limiting load for wear
𝑃𝑃𝑤𝑤 = 𝑘𝑘𝑤𝑤 𝑘𝑘𝑛𝑛 𝐹𝐹 𝑚𝑚𝑡𝑡 𝑁𝑁 / 𝑐𝑐𝑐𝑐𝑐𝑐 2 ψ
kn = 2 Ng / (Np + Ng) & N = NP for Pinion hardness
= 2 Np / (Np + Ng) & N = NG for Gear-wheel hardness

Acceptance criterion:
If Pw ≥ Pd
Or increase hardness and/or size
Gears in mesh Kw, MPa
pinion Gear φ = 15° φ = 20°
Steel Steel 𝐻𝐻𝐻𝐻 2 𝐻𝐻𝐻𝐻 2
� � 1.4 � �
1000 1000
Steel Cast iron 𝐻𝐻𝐻𝐻 2 𝐻𝐻𝐻𝐻 2
1.5 � � 2.1 � �
1000 1000
Cast iron Cast iron 𝐻𝐻𝐻𝐻 2 𝐻𝐻𝐻𝐻 2
HB = 0.5 (BHNp + BHNg) 4� � 5.6 � �
1000 1000
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 Straight Bevel Gear (SPG)

𝐴𝐴0 − (𝐹𝐹⁄2)
𝐷𝐷𝑎𝑎𝑎𝑎 = × 𝐷𝐷𝐺𝐺
𝐴𝐴0
Dav is the pitch radius at the
midpoint of the tooth

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 SBG Force Analysis

rav : the pitch radius at the

midpoint of the tooth

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 Stress on SBG
Static Bending Stress on tooth
𝑘𝑘𝑣𝑣 𝑊𝑊 𝑡𝑡 𝐴𝐴0
σ = 𝑘𝑘𝑠𝑠 𝑘𝑘1
𝐹𝐹 𝑚𝑚𝑡𝑡 𝑌𝑌 𝐴𝐴0 − 𝐹𝐹

Dynamic load on tooth

𝑡𝑡
𝑠𝑠
𝑃𝑃𝑑𝑑 = 𝑊𝑊 + 𝑠𝑠 = 𝑘𝑘𝑑𝑑 𝑌𝑌 + 𝑊𝑊 𝑡𝑡
0.15 Where:
1 + 𝑣𝑣 √𝑠𝑠
Endurance load on tooth
𝑃𝑃𝑒𝑒𝑒𝑒 = 𝑆𝑆𝑒𝑒 𝑌𝑌 𝐹𝐹 𝑚𝑚
Limiting load for wear
𝑃𝑃𝑤𝑤 = 𝑘𝑘𝑤𝑤 𝑘𝑘𝑛𝑛 𝐹𝐹 𝑚𝑚 𝑁𝑁𝑝𝑝 / 𝑐𝑐𝑐𝑐𝑐𝑐 𝛾𝛾
kn = 2 Ng / (Np + Ng) & γ = γP N = NP for Pinion hardness
= 2 Np / (Np + Ng) & γ = γG N = NG for Gear-wheel hardness
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 Worm Gear

A right hand helical gear or right hand

worm is one in which the teeth twist
clockwise as they recede from an observer
looking along the axis.

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Types of worm gear

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 Worm Gear Nomenclatures
𝑑𝑑𝐺𝐺 = 𝑁𝑁𝐺𝐺 𝑚𝑚𝑡𝑡

𝑃𝑃𝑥𝑥 = 𝜋𝜋 𝑚𝑚𝑡𝑡

𝐿𝐿 = 𝑁𝑁𝑤𝑤 𝑃𝑃𝑥𝑥
𝐿𝐿
tan 𝜆𝜆 =
𝜋𝜋 𝑑𝑑𝑤𝑤
𝐶𝐶 0.875 𝐶𝐶 0.875
≤ 𝑑𝑑𝑤𝑤 ≤
3.0 1.7

F ≅ 2 𝑚𝑚𝑡𝑡 �1 + 𝑑𝑑𝑤𝑤 ⁄𝑚𝑚𝑡𝑡

𝑑𝑑𝑤𝑤 −1
𝐹𝐹
(Contact Ratio) 𝐶𝐶𝐶𝐶 = sin (𝑟𝑟𝑟𝑟𝑟𝑟)
𝜋𝜋 𝑚𝑚𝑛𝑛 𝑑𝑑𝑤𝑤
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Worm Gear Force Analysis

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 Stress on Worm Gear
Static Bending Stress on tooth
𝑘𝑘𝑣𝑣 𝑊𝑊 𝑡𝑡
σ = 𝑘𝑘𝑠𝑠 𝑘𝑘1
𝐹𝐹 𝑚𝑚𝑡𝑡 𝑌𝑌
Dynamic load on tooth
6 + 𝑣𝑣
𝑃𝑃𝑑𝑑 = 𝑊𝑊𝑡𝑡 ×
6

Endurance load on tooth

𝑃𝑃𝑒𝑒𝑒𝑒 = 𝑆𝑆𝑒𝑒 𝑌𝑌 𝐹𝐹 𝑚𝑚𝑡𝑡 Worm of hardened steel (BHN ≥ 250)
Gear Material k
Cast iron or Steel 0.144
Limiting load for wear Manganese Bronze 0.230
𝑃𝑃𝑤𝑤 = 𝑑𝑑𝐺𝐺 𝐹𝐹 𝑘𝑘 Phosphor Bronze 0.288
Non Metallic 0.360

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 Worm Gear Efficiency
Sliding Velocity
Efficiency

0.042
𝑓𝑓 = 𝑓𝑓𝑓𝑓𝑓𝑓 𝑣𝑣𝑠𝑠 𝑢𝑢𝑢𝑢 𝑡𝑡𝑡𝑡 2.8 𝑚𝑚/𝑠𝑠𝑠𝑠𝑠𝑠
(𝑣𝑣𝑠𝑠 )0.28
𝑣𝑣𝑠𝑠
𝑓𝑓 = 0.025 + 𝑓𝑓𝑓𝑓𝑓𝑓 𝑣𝑣𝑠𝑠 > 2.8 𝑚𝑚/𝑠𝑠𝑠𝑠𝑠𝑠
305

Heat Generation
HG = Input Power × (1 - η) watt

Heat Dissipation
A: area of housing
HD = A (t2 – t1) k watt
K = 0.0378 (W/mm2)/°C
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