Chapter 2:

Transmission System

Gears and Gear Train

EPT 314
 Example: engine of a containership
– Optimum operating speed of the engine about 400 RPM
– Optimum operating speed of the propeller about 100 RPM
– Need reduction gear

2
Connecting the main engine to the propeller
through a reduction gear

Propeller, Output flange

operates at about
100 RPM Engine
Gear

Engine operates at
about 400 RPM

3
Source Power transmission components End user
 3.1 Gear systems
Play HUGE role..
Example car engines, drills, lathe, mills, printers,
mechanical watch…etc.
•They are used to reverse direction of rotation, for example
when selecting reverse in your car.
•Gears are also used to transfer rotational motion to a
different axis.
•Gears are used to alter the speed of rotation which in the
same way can be used to alter the end turning force or
torque available.
 3.1 Gear systems

1. Gear Trains
2. Chain-Sprocket systems
3. Worm and Worm-gear
Systems
4. Friction-Gear
(toothless)Systems
5. Belt and Pulley Systems
 3.2 Type of gear combinations
Spur Gears – tooth profile is parallel to the axis of
rotation, transmit motion between parallel shafts.
Used in electric screw driver, oscillating sprinkler,
windup alarm clock, washing machine and clothes
dryer.
 3.2 Type of gear combinations
Internal Spur Gears – Not much different from spur
gear.
These gear by appearance shows pitch surface that Is
cylindrical.
 3.2 Type of gear combinations
Helical gears – Helical gears have angled teeth which
form a curve that resembles a segment of a helix.
Helical gears are meshed in parallel or crossed
orientations
• More refined operation and run much smoother and
quieter than spur gears for example.
.
Continue…

• Helical gears can operate at high speeds and transmit

large amounts of torque.
• A disadvantage of helical gears is the thrust
generated by the curved teeth when under load, this
is usually handled by a suitable thrust bearing to help
take this load.
 3.2 Type of gear combinations
Double Helical Gear - A double helical gear is similar to
two separate helical gears joined together but
mirrored, this helps eliminate the thrust that a single
helical gear would create as in effect there is equal
thrust in each direction cancelling each other out
.
 3.2 Type of gear combinations
Rack and pinion - is used to transfer rotational movement into
linear movement. The pinion which is the circular gear drives
the rack (the straight toothed section) in a linear direction.
• Typically the pinion is used to drive the rack but this is not
always the case.
• Examples of rack and pinion use include stair lifts, car
steering, lock gates
.
 3.2 Type of gear combinations
Bevel gears- Bevel gears have a cone shape which
enables them to mesh at various angles except 0 and
180 degrees,
• That is not to say a single bevel gear can work at
multiple angles, the bevel gears must be cut to suit a
specific meshing angle.
Continue…

• The teeth of a bevel gear can be straight cut, similar

to that of a spur gears teeth, or they can be curved
along their length with each tooth sitting at an angle
(Spiral bevel gear).
• Zerol bevel gears are too curved along their length
but are not angled. Bevel gears are suited best to low
speed applications usually sub 5m/s.
 3.2 Type of gear combinations
Worm gear- The worm
resembles the thread of a
screw, and are usually
meshed with a worm
wheel which looks similar
to a typical spur gear.
• Worm gears are an
excellent way to increase
torque output while
reducing rotational
speed.
 Continue…

• Worm drives have ratios varying from around 10:1 to 500:1,

• Disadvantage -not very efficient, a lot of energy can be
wasted due to the sliding action of the gear teeth.
• The worm itself can have
1 or more teeth, although
1 tooth that follows
around the length of the
worm several times can
look like more than one
tooth being present.
• A worm with one tooth is
called a single thread or
single start, while a worm
with more than one tooth
is called a multiple thread
or multiple start.
 3.2 Type of gear combinations
Planetary gear-The most basic form of planetary
gearing involves three sets of gears with different
degrees of freedom. Planet gears rotate around axes
that revolve around a sun gear, which spins in place.
A ring gear binds the planets on the outside and is
completely fixed.
 3.3 Gear Ratio

• Understanding Gear Ratios

Ratio 1:2

A’s rotational
speed is half that
of gear B
 Gear Efficiency
What about CVT gearbox?
Gear Efficiency
• Gears (spur gears, helical gears) efficiency is
high. (95-99%)
• Since gear transmit high power, amount of
losses is significant.
• Types of losses in a gear
– Load independent
– Load dependent
 Gear Efficiency
Load-Independent losses in gearboxes
Vary with speed but not with load
• Other components in the system
– Bearings, seals.
• The gear it self
– Trapping and squeezing (fluid, lubricant)
– Gear immersion depth and area
– Rotating speed
– Lubricant viscosity and density
 Gear Efficiency
Load – dependent losses
Increase with increasing load
• Tooth friction is recognized as
the main source of dissipation
– Modify the tooth geometry in
order to reduce the specific
sliding
– Reduce the friction coefficient
between the gear teeth
• Friction coefficient depends on
the lubrication regime
Conclusion
• Power losses in gear systems are associated
primarily with tooth friction and lubrication
churning losses
• Churning losses are relatively independent of the
nature of the gears and the gear ratios - they are
primarily related to the peripheral speed of the
gears passing through the fluid
• The frictional losses are related to the gear
design, the reduction ratio, the pressure angle,
gear size, and the coefficient of friction.
• Gear teeth have a complex INVOLUTE shape
-Choosing gear
-Placing gear
- torque/speed
 How to choose a gear?
DP (Diametral pitch), PA (Pressure angle),width,
No. of Teeth.

Example: 10 DP, 20° PA, 1 inch wide gear and 40

teeth.
 How to choose a gear?
Diametral Pitch (P)
P = N/D
Where
N =# of teeth
D= Pitch diameter
D
 How to choose a gear?
Pressure Angle
• The preferred pressure angle in use today is 20°,
a good compromise for power and smoothness,
with 25,22.5 and 14.5.
• In general, higher pressure angles provide higher
strengths and lower tendency to experience
tooth tip interference, but are susceptible to
noise and higher bearing loads.
• Low pressure angles are quieter and smoother,
have lower bearing loads and lower frictional
forces, but are susceptible to undercutting at low
numbers of teeth.
Gear interference
 For a pinion meshing with a rack
Tooth form Min. no. of
teeth
14½ ° , involute, full depth 32
20 ° , involute, full depth 18
25 ° , involute, full depth 12

For a 20°, Full-depth pinion meshing with

a gear
Number of pinion Maximum number
teeth of gear teeth
17 1309
16 101
15 45
14 26
13 16
 How to choose a gear?
No of teeth
N= P.D
Where
P= Diametral pitch
D= Pitch Diameter
 Example Problem
A pinion of 24 teeth drives a gear of 60 teeth at
a pressure angle of 20˚. The pitch radius of the
pinion is 38 mm and the outside radius is 41
mm. The pitch radius of the gear is 95 mm. The
outside radius is 98.5 mm. Calculate the length
of action and contact ratio.
 Example Problem
Two equal size spur gear in mesh have 36 no. of
teeth, 20˚pressure angle and 6 mm module. If
the arc of contact is 1.8 times circular pitch, find
the addendum.
 How to place a gear train?
• What is Center
distance (c)?
• Important for design engineer
Mesh point of the gears should be at the
location at pitch circle intersect.
If too close or too far; lost energy, reduce
efficiency
 Example
You are designing a device requiring two 10DP and 20° PA gears to mesh and
transmit power. The smaller gear has 20 teeth and is being driven by
motor at 1800 rpm. The larger gear need to turn at 600 rpm. Determine all
the value of following parameter.
Parameter G1 G2
Rotational speed
Gear ratio
Diametral Pitch (DP)
No of teeth (N)
Pitch Diameter (D)
Center distance

Remember what is Pitch Diameter??

You are designing a device requiring two 10 DP and 20° PA gears to mesh and transmit
power. The smaller gear has 40 teeth and is being driven by motor at 1800 rpm. The
larger gear need to turn at 600 rpm. Determine all the value of following parameter.
Parameter G1 (Driver/pinion) G2 (Driven)
Rotational speed 1800 600
Gear ratio 3:1
Diametral Pitch (DP) 10 10
No of teeth (N) 40 120
Pitch Diameter (D) 4 12
Center distance 8

For a 20°, Full-depth pinion meshing with a

gear
Number of pinion Maximum number of
teeth gear teeth
17 1309
16 101
15 45
14 26
13 16
 Torque
Gear Ratio DO NOT increase power.
Power (in) = Power (out) →Ideal condition

Real life?
Power = Torque . Speed
POWER (W) watt , N.m/s……. Lets review.
• A machine rotates with speed 3000 rev/min
(rpm) and consumes 5 kW. Calculate the
torque.
 Example 1
• A motor with speed 100 rad/s with 10 N.m of
torque. Calculate power. ??
 Example 2
If a shaft from electric motor rotate at 2300 rpm
with 4kW of power, calculate torque.
 Example 3
A small transmission in a mixer has a 12 teeth
gear on the motor shaft driving 72 tooth gear
on d mixer blade. The motor is running at
1800rpm. What is the mixer blade speed?
 Example 4
A mixer is powered by 2000 watt electric motor
with 1500 rpm. There is spur gear attached at
motors shaft(Gear A) that mesh with another
gear (Gear B). If the required speed on the
mixer blade is 500 rpm, determine no. teeth
of gear A n B, Center distance between both
gear for assembly. Given the diametral pitch is
10 and 20°PA
Example 4
Clockwise
N=40, 3000 rpm
A MOTOR
N=60
C B
N=10

N=30
D Output shaft