Fundamenta ls

Objective: To design two meshing gear for a particular applications

Problem Statement:
Design a speed reducer such that the input speed is 1800 rev/min and the output speed
is 1200 rev/min (i.e. a reduction ratio of 3:2).
Approach:
When two gears are in mesh, their pitch circles roll on one another without slipping.
Designate the pitch radii as r1 and r2 and the angular velocities as ω1 and ω2,
respectively. Then the pitch-line velocity is

Thus the relation between the radii on the angular velocities is

The gear pitch diameters would be in the same ratio (i.e. 3:2)

Note: These dimensions are governed by space constraints and designer experience
 Fundamenta ls
Given: N1 = 18 teeth, N2= 30 teeth, P = 2 and ϕ = 20°
Required: Gear profile for above requirements

Step 1: Determine the pitch diameters: d1 and d2

d1 = N1/P = 18/2 = 9 in.; d2 = N2/P = 15 in.
Two gears in mesh should have the same diametral pitch P
Step 2: Locate the centers O1 and O2
Center distance: C = (d1+ d2)/2 = (9+ 15)/2=12 in.
Step 3: Draw Pitch Circles
r1 = (d1/2) = 4.5 in. r2 = (d2/2) = 7.5 in.
Step 4: Draw Common Tangent ab
The point of tangency of the pitch circle is the pitch point P.
Step 5: Draw line of action cd at an angle ϕ= 20o with respect to common tangent
ab : pressure angle = 14.5, 20, 22.5 or 25°, (14.5° not in use anymore)
 Gear Profile Construction

2, 3, 4, 5 6, 7, 8, 8

Dedendum Circle
ω1
Pitch Circle
O1
Base Circle
c r1
Involute
ϕ
Addendum Circles
a b

Involute
P d

r2 Pitch Circle
ω2
Base Circle

Dedendum O2
Circle
 Fundamenta ls
Given: N1 = 18 teeth, N2= 30 teeth, P = 2 and ϕ = 20°
Required: Gear profile for above requirements
Step 6: Draw base circles tangent to line of action cd
rB1 = (r1cos 20) = 4.23" Base circles are fundamental to a gear
rB2 = (r2 cos 20) = 7.05”
Step 7: Generate the involute on each circle (as shown in previous presentation)
Step 8: Draw addendum and dedendum circles
Note that a and b values
Ra1 = r1 + a = r1 + (1/P) = 4.5 + (1/2) = 5"
will be the same for both
Ra2 = r2 + a = r2 + (1/P) = 7.5 + (1/2) = 8"
gears as they depend only
Rb1= r1 - b = r1 - (1.25/P) = 4.5 + (1.25/2) = 3.875" on P
Rb2= r2 - b = r2 - (1.25/P) = 7.5 + (1.25/2) = 6.875"

Step 9: Draw one tooth on each gear (using template)

t = p/2 = 𝜋 /(2P) = 0.785 in. Circular pitch: p = 𝜋/P

p should be the same for both gears
 Gear Profile Construction

2, 3, 4, 5 6, 7, 8, 8

Dedendum Circle
ω1
Pitch Circle
O1
Base Circle
c r1
Involute
ϕ
Addendum Circles
a b

Involute
P d

r2 Pitch Circle
ω2
Base Circle

Dedendum O2
Circle
 Fundamenta ls
Given: N1 = 18 teeth, N2= 30 teeth, P = 2 and ϕ = 20°
Required: Gear profile for above requirements
Step 10: The rest of the teeth are drawn using p and t (using template after the
points have been marked on the pitch circle)
Step 11: Find the clearance:
c = b-a = 0.625-0.5 = 0.125” (The same for both gears)

Step 12: Draw the fillet radius 𝑟𝑓 (radial line or use standard value = r/35)

The construction is finished when these fillets have been drawn.

The process can be auto mated using computer program.

Online Gear Template Generator

https://geargenerator.com/
 Point of Contacts & Angle of Action

Fillet Radius

Clearance A template for drawing

gear teeth.
Cut from a sheet of 0.015 in clear plastic,
being careful to locate the gear centers
properly with respect to each involute

Initial Contact Point (a)

addendum (driven) pressure line

End of contact Point (b),

addendum (driver) pressure line.

10, 11, 12
 Example

Given: Solution:
Np = 16 We know that Pp=π
Ng = 40
P= 2 Also d = pN 𝜋
a = 1/P
b = 1.25/P ϕ Therefore the center distance is
=20o
The base circle radius is given by: rB = r cos ϕ
Reqd:
p = ? O1O2=?
r B =?
 Example

Given: Solution:
Np = 16 Ng Designating d’P and d’G as the new pitch-circle diameters, the 14 -in
= 40 P= 2 increase in the center distance requires that
a = 1/P
b = 1.25/P
ϕ =20o
Since, the velocity ratio does not change, therefore:
Reqd:
d‘ p = ? Solving Eqs. (1) and (2) simultaneously yields
d‘ G = ?
ϕ=?
 Point of Contacts & Angle of Action
The initial contact will take place when the flank of the driver comes into contact
with the tip of the driven tooth (i.e. on the Addendum of the driven gear).
The line of action passes through this point (Normal to the common tangent to both
contacting teeth at point of contact)
Therefore the initial point of contact (a) is the intersection of line of action with the
addendum of the driven gear
Similarly the end of contact point (b) is the intersection of line of action with the
addendum of the driver gear

Based on initial point of contact, pitch point and the end of contact following angles
are defined
Angle of approach
Angle of recess
Angle of action (sum of above two) over which the meshed teeth are in contact
Driver

Driven
 Point of Contacts & Angle of Action

Fillet Radius

Clearance A template for drawing

gear teeth.
Cut from a sheet of 0.015 in clear plastic,
being careful to locate the gear centers
properly with respect to each involute

Initial Contact Point (a)

addendum (driven) pressure line

End of contact Point (b),

addendum (driver) pressure line.

10, 11, 12
 Contact Ratio
Contact ratio indicates the average number of pairs
of teeth in contact.
p: Circular pitch and qt: arc of action b
𝑞𝑡
𝑚𝑐 = a
𝑝
𝑚𝑐 = 1 𝑞𝑡 = 𝑝 driver

when a tooth is just beginning contact at a,

the previous tooth is simultaneously
ending its contact at b
𝑚𝑐 = 1.2 𝑞𝑡 =1.2 𝑝 (Recommended value)
when one pair of teeth is just entering contact at
a, another pair, already in contact, will not yet
By considering te geometry the
have reached b (as shown in fig).
alternate expression is:
Account for inaccuracies in mounting
mc< 1 would cause impact between the teeth 𝐿𝑎𝑏
𝑚𝑐 =
as well as an increase in the noise level. 𝑝 cos ∅
Tooth Size

Shigley’s Mechanical Engineering Design

 Tooth Sizes in General Use

Table 13–2

Shigley’s Mechanical Engineering Design

Standardized Tooth Systems (Spur Gears)

Table 13–1

Shigley’s Mechanical Engineering Design

 Standardized Tooth Systems
 Common pressure angle f : 20º and 25º
 Old pressure angle: 14 ½º
 Common face width:

3p  F  5p

p
P
3 5
F
P P

Shigley’s Mechanical Engineering Design

Shigley’s Mechanical Engineering Design
Shigley’s Mechanical Engineering Design
Shigley’s Mechanical Engineering Design
Shigley’s Mechanical Engineering Design
 Rack and Pinion
a rack as can be considered as a spur gear having an infinitely large
pitch diameter having:
an infinite number of teeth and
a base circle at an infinite distance from the pitch point.

The sides of involute teeth on a rack are straight ϕ

lines making an angle to the line of centers equal
to the pressure angle.
Corresponding sides on involute teeth are
parallel curves;
the base pitch is the constant and fundamental
distance between them along a common normal.
The base pitch (pb) is related to the circular
pitch (pc) by the equation

pb = pc cos ϕ
 Internal Gear
Both gears have their centers of rotation on the same side of the pitch point.
The positions of the addendum and dedendum circles with respect to the pitch circle
are reversed
The base circle of the internal gear lies inside the pitch circle near the addendum
circle.
The operating diameters of the pitch circles of a pair of meshing gears need not be
the same as the respective design pitch diameters of the gears.
On increasing the center distance, two new operating pitch circles are created having
larger diameters because they must be tangent to each other at the pitch point
Shigley’s Mechanical Engineering Design