GEARS

A gear is a rotating machine part

having cut like teeth which
mesh with another toothed part
to transmit torque.
Classification of gears can be done
according to the relative position of the
axes of revolution into three types.
Gears for Gears for non-
Gears for Parallel Intersecting Shafts intersecting
shafts Shafts

• Spur • Straight Bevel • Hypoid

• Helical • Spiral Bevel • Worm
• Herringbone
• Rack & Pinion
Spur Helical

Bevel Worm
• DP = Pitch diameter of pinion
• DG = Pitch diameter of gear
• TP = No. of teeth for pinion
• TG = No. of teeth for gear
• Pd = diametral pitch (Tx/Dx) , constant
for meshing gears
• Pc = circular pitch (πDx/Tx ) , constant
for meshing gears
• M = module (1/Pd), mm if not given
• a = addendum (1/ P )
• d = dedendum (1.157/Pd) for ϕ = 14.50,
22.50 and (1.25/Pd) for ϕ = 200 , 250
• C = clearance (d – a)
• Do = outside dia. (D + 2a)
• W = whole depth (a + d)
• Wr = working depth (W – c)
• TT = tooth thickness (Pc – B)/2
• C = center distance (Dp + Dg)/2
• VR = velocity ratio = TP/TG = NG/NP
• PdPc = π
1. Two shafts are connected
by spur gears. The pitch
radii of gears A and B are
100 mm and 500 mm
respectively. If shaft A
makes 800 rpm and is
subjected to a resisting
torque of 113 N-m, what is
the torque in shaft B?
 F𝑟
𝑃 = 𝐹𝑡𝑉 𝑡𝑎𝑛ϕ =
Ft
2
𝐹𝑛 = 𝐹𝑡 + 𝐹𝑟 2
 𝑇𝐴 𝑇𝐵
=
𝑅𝐴 𝑅 𝐵

565 N - m
2. Find the tooth
thickness on the tooth
circle of a 20 degree full
depth involute tooth
having a circular pitch
of 1.25 in. and whole
depth of 0.75 in.
16mm
3. A pair of gear/pinion of 45
teeth and 15 teeth,
respectively, has a center
distance of 40 cm, addendum
at 0.725/p and dedendum at
1/p. The gear pressure angle
is 20 degrees. Compute for
the diametral pitch in teeth
per cm.
 𝑇𝑔 + 𝑇𝑝
=
2𝑃𝑑

0.75TPC
4. A pinion and gear set are
carefully cut in a 20° full
depth design. The 16-teeth
steel pinion and 72-teeth cast
iron gear transmit 50 kW
power when the pinion turns
1400 rpm. The face width is 90
mm and the module is 8 mm.
Find the center distance
between pinion and gear.
 𝑇𝑔 + 𝑇𝑝 1
𝐶= 𝑀=
2𝑃𝑑 𝑃𝑑

352 mm
5. A gear set having a
gear ratio of 3 is to be
used at a center
distance of 16 inches.
If the gear has 80
teeth, what must be
the circular pitch?
23.9mm
6. Compute for the
circular pitch, in inches,
of a pair of gear and
pinion with ratio of 5.
The center distance
indicated is at 18. The
gear has 90 teeth and the
pinion has 18 teeth.
1.047
7. A gear of 80 teeth and
a pinion of 20 teeth has
a gear and pinion ratio
of 4. Find the center
distance in inches, if the
circular pitch is 0.885
in.
14.1
8. A double-threaded right
handed worm gear transmits 15
hp at 1150 rpm. The pitch of the
worm is 0.75 inches and pitch
diameter of 3 inches. The
pressure angle is 14½ deg and
the coefficient of friction is 0.12.
Find the tangential force on the
worm, tangential force on the
gear and the separating force in
pounds.
 𝑃𝑜 = (𝐹𝑡𝑤 )(𝑉)
𝑠𝑖𝑛ϕ𝑛
𝐹𝑠 = 𝐹𝑡𝑤( )
𝑠𝑖𝑛λ𝑐𝑜𝑠ϕ𝑛 + 𝑓𝑐𝑜𝑠λ
𝑐𝑜𝑠λ𝑐𝑜𝑠ϕ𝑛 − 𝑓𝑠𝑖𝑛λ
𝐹𝑡𝑔 = 𝐹𝑠( )
𝑠𝑖𝑛ϕ𝑛
𝐿
𝑡𝑎𝑛ϕ𝑛 = 𝑡𝑎𝑛ϕ𝑐𝑜𝑠λ 𝑡𝑎𝑛λ =
π𝐷𝑚
9. A pair of straight
tooth bevel gears
connects a pair of shaft
at 90 deg. The velocity
ratio is 3 is to 1. What
is the cone pitch angle
of each gear?
𝐴 = ϴ𝑝 + ϴ𝑔
10. Two helical gears
transmit 500 hp at
3600 rpm. What should
the bore diameter of
each gear be if the
allowable stress in gear
shafts is 12,500 psi?
11. A steel pinion having a diameter of
about 254 mm meshes with a steel gear
which turns at 1/3 the angular speed of
the pinion. The torque is 3222 kg-cm
(18,000 in-lb). The angle of cut of the teeth
is to be 20 deg. Assume the width of the
face to be 9 times the normal pitch, the
normal diametral pitch to be 4, and the
Brinell hardness of the gear and pinion to
be 200 and 250, respectively. The teeth
are to be 14.5 deg composite form.
Determine the diametral pitch, the
number of teeth required and the
hardness of the gear and the pinion.
𝑇 𝑝 = 𝐷 𝑝 𝑃𝑑
𝑇𝑝 = 37.58 = 37

𝑇𝑔 = 111
12. The maintenance shop of Philippine Air
Lines has a motor operated hoisting winch
which consists of the following mechanical
parts: in mesh is a 56 tooth worm wheel at
shaft “B” directly below. Compounded on shaft
“B” is a 20-tooth 5-module pinion in mesh with
a spur gear keyed on shaft “C” with a
horizontal centerline distance of 150 mm.
Mounted on the same shaft “C” with a
horizontal center line is a 200-mm diameter
hoisting drum. The cable wrap around the
drum sustain a load of 500 kg. If the efficiency
of the mechanical system is 65%, calculate the
power on motor shaft ‘A” when using the load.
Compounded on shaft A is double-threaded left
handed worm at 1750 rpm.
Wire Ropes
• Individual wires are twisted into strands, and then
the strands are twisted around a hemp or steel
center to form the rope.
• The central element is an independent wire rope
core (IWRC).
• Wire rope is made with two types of winding, the
regular lang lay and the lang lay rope.
• Regular lang lay rope – is the accepted standard,
has the wire twisted in one direction to form a
strands and the strands twisted in opposite
direction to form a rope.
• Lang lay ropes have the wires in the strand and the
strands in the rope twisted in the same direction,
the outer wires run diagonally across the axis of the
rope.
Rope Sizes with Corresponding applications
• 6 x 7 – haulage, tramways,
guy wires
• 6 x 19 – general [purpose rope,
hoists, cranes, drilling,
elevators
• 6 x 37 – high speed elevators,
cranes, hoists
• 8 x 19 – extra flexible hoisting
rope applications
Design Calculations
Ft = tensile force due to the load
(including acceleration force)
Fb = equivalent bending load due to
the curvature of the sheave or drum
Fu = ultimate strength
Sb = equivalent bending stress
dw = wire diameter (in)
D = sheave or drum diameter
d = diameter of rope
E = modulus of elasticity (from Tables)
FS = factor of safety
Am = cross sectional area of metal
Wr = rope weight
h = height (ft)
Wire Rope Design Formula
𝐹𝑢
Factor of safety =
𝐹𝑇
Fu = 76000 d 2
6 x 7 and 6 x 19
2
Fu = 75000 d 6 x 37 and 8 x 19
𝑊𝑙𝑜𝑎𝑑 𝑎
FT = T + FB ,T = 𝑛𝑟𝑜𝑝𝑒𝑠
+ Wr 1+
𝑔

Wr = 1.58 2
dh FB = dwEAm/Ds
Rope dw Am E
6x7 0.106d 2
0.38d 13x10 6

6 x 19 0.063d 2
0.38d 12x10 6

6 x 37 0.045d 2
0.038d 13x106

8 x 19 0.050d 0.035d 2
13. A wire rope lifts a load
of 10 kips at a maximum
speed of 1000 fpm,
attained in 5 seconds
starting from rest. The
rope has a cross sectional
area of 0.4 in . Compute
2

the maximum tensile

stress on the rope in ksi.
14. An elevator weighs
1000 pounds and is
supported by a 5/16” wire
rope, 1500 feet long. When
the elevator carries a 1500-
lb load, the rope elongates
6 inches more. What is the
modulus of elasticity of the
rope?
15. In an office building, the
elevator rises 1200 ft with an
operating speed at 1000 ft/min
and reaches full speed at 35 ft.
Assume a rope drive of 6 x 19
cast-steel ropes, 36 inches
sheave. The load of the elevator
weighs 2 tons. Determine the
number of 5/8 in. ropes required
if the factor of safety is 5.
 𝐹𝑢
Factor of safety =
𝐹𝑇
Fu = 76000 d 2 FT = T + F B
𝑊𝑙𝑜𝑎𝑑 𝑎
T= + Wr 1+
𝑛𝑟𝑜𝑝𝑒𝑠 𝑔

Wr = 1.58 2
dh Vf 2+ 2
Vo = 2aS
FB = dwEAm/Ds
Rope dw Am E
6 x 19 0.063d 0.38d 2 12x106
 𝐹𝑢
Factor of safety =
𝐹𝑇
Fu = 76000 d 2 FT = T + F B
𝑊𝑙𝑜𝑎𝑑 𝑎

1.42≈
T=
2
𝑛𝑟𝑜𝑝𝑒𝑠
2
+ Wr
𝑅𝑂𝑃𝐸𝑆
W = 1.58 d h V + V = 2aS 2
1+
2
𝑔

r f o
FB = dwEAm/Ds
Rope dw Am E
6 x 19 0.063d 0.38d 2 12x106
Machine Shop
16. How long will it
take to drill a hole
through a 10 cm thick
steel plate if the drill
feed is 0.1 mm per rev
and a ¼ in. diameter
drill is turning at 750
rpm?
80 sec
17. How long will it
take to cut a 4-in long
thread at 100 rpm if
the threading machine
has a configuration of
20 threads per inch?
48 sec
18. How long would it
take to cut by
oxyacetylene gas cutter
crosswise a 4 ft x 20 ft x 1
in.thick steel plate if
oxyacetylene machine can
finish cutting a 10 ft long
steel in 12 min?
288 sec
19. On the average, how long
would it take to cut manually
using an oxyacetylene gas
cutter to cut crosswise a 4 ft
x 20 ft x 1 in. steel plate into
4 sheets of 4 ft x 5 ft x 1 in.
steel plates? The manual
cutting rate of oxyacetylene
gas cutter is 12 min in 8 to
12 ft length of steel plate.
14.4 min
20. On the average, compute
the time to cut manually
using an oxyacetylene gas
cutter to cut lengthwise two 8
ft x 20 ft x ¾ in. steel plates
into four 4 ft x 20 ft x ¾ in
steel plates. The manual
cutting rate of oxyacetylene
gas cutter is 12 min in 11 ft
to 16 ft length of steel plate.
35.6 min
21. Determine the most economical
acetylene gas consumption in cu. ft
to manually cut crosswise a 4 ft x 20
ft x 1 in. thick steel plate into five
sheets of 4 ft x 4 ft x 1 in. steel
plate. The manual cutting rate of
oxyacetylene gas cutter is 12 min in
11 ft to 16 ft length of steel plate.
Oxygen consumption is 60 cu. ft and
acetylene gas rate is 10 cu. ft per
hour.
2.4 ft3
22. With an electric arc
welding rate of 18
in/min, how long will it
take to weld a ½ in.
thick plate by 3 ft long
seam?
2 min
23. How long will it
take to mill a ¾” by 2”
long keyway in a 3”
diameter shafting with
a 24-tooth cutter
turning at 100 rpm and
0.005” feed per tooth?
0.166 min