2022.09.21 Chapter 6 Gear Drive

Chapter 6 Gear drives
https://www.rexnord.com/blog/articles/gear/
1
types-of-gears
PGS.TS Nguyễn Hữu Lộc
2
Contents
6.1 Introduction
6.2 Geometry of gear drives
6.3 Forces acting on gears and shafts
6.4 Losses and Efficiency of gear drives
6.5 Tooth failure and criteria of calculation
6.6 Materials and Allowable stress
6.7 Design and analysis of straight spur gear
6.8 Design and analysis of helical spur gears
6.9 Bevel gear
6.10 Exercise
3
Learning Outcoms
• Select the materials and determine the allowable
stresses for gears (L03.2)
• Understand the types of gears (L07.2)
• Analyze and calculate the forces acting in a gear
(L01.4)
• - Determine the tooth failures and choose a criteria of
calculation (L02.2)
• - Design and analyze the teeth for surface and
bending strength (L04.5)
• - Use the CAD softwares to select the gear drives
(L05.3)
4
6.1 Introduction - Spur gear: straight, helical
- Bevel gear: Straight, helical, Spiral, Arc- toothed
A gear drive has three main

functions:
1. to increase torque from
the driving equipment
(motor) to the driven
equipment,
2. to reduce the speed
generated by the motor,
3. and/or to change the
direction of the rotating
shafts.
The connection of this
equipment to the gear box
can be accomplished by the
use of couplings, belts,
chains, or through hollow
shaft connections.
5
6.1 Introduction https://www.iqsdirectory.com/articles/gear/types-of-gears.html
Types of gears
https://www.cedengineering.com/userfiles/Basic%20Fundamentals%20of%20Gear
%20Drives%20R1.pdf 6
6.1 Introduction
Straight spur Helical spur gear Bevel gear
Herringbone Gear 7
PGS.TS Nguyễn Hữu Lộc Planetary Worm – Worm gear
6.1 Introduction
8
6.1 Introduction
Screw gear - Crossed helical gear (trụ xoắn)
Spiral bevel Hypoid 9

6.1 Introduction
10
6.1 Introduction
https://encyclopedia2.thefreedictionary.com/Gear+Drive 11
6.1 Introduction
Gear wheel. Mechanical transmission system. Silhouette vector

12
6.1 Introduction
Profile of gears: Gear profiles should satisfy the law of
gearing. The profiles best suited for this law are:
1. Involute; 2. Cycloidal
The tooth profile of an involute gear is
the involute of circle, which is the curve that would
be traced by a point on a line that rolls on the
circumference of a circle.
13
6.1 Introduction
An epicycloid is formed when a circle rolls on the outside of a base circle.
Hypocycloid is formed when a circle rolls on the inside of a base circle.

14
6.1 Introduction
Bánh răng cicloid

Harmonic drive Cycloid gear
(Bánh răng sóng)
15
6.1 Introduction
Spur gear Helical gear

Wildhaber-Novikov Circular Arc Gears (Bánh răng Novicov ) 16
6.1 Introduction
Applications of gear drive
17
6.1 Introduction
Gear Drive-Infeed Rollers Pete Robinson's cam gear drive for Ford 427
SOHC V-8
18
PGS.TS Nguyễn Hữu Lộc Applications of gear drive
6.1 Introduction
Car differential
https://www.google.com/search?q=Car+differential&tbm=isch&ved=2ahUKEwjWk
4v74OfyAhUIYJQKHU7qANEQ2-
cCegQIABAA&oq=Car+differential&gs_lcp=CgNpbWcQAzIFCAAQgAQyBAgAEB
4yBAgAEB4yBAgAEB4yBAgAEB4yBAgAEB4yBAgAEB4yBAgAEB4yBAgAEB4yB
AgAEB5Q4YwFWOGMBWC_kwVoAHAAeACAAV6IAV6SAQExmAEAoAEBqgEL
Z3dzLXdpei1pbWfAAQE&sclient=img&ei=sq00YdbyBYjA0QTO1IOIDQ&bih=468&
biw=960 19
6.1 Introduction
Typical watch escapement and gear train
20
6.1 Introduction
Speed
Gearbox
https://www.google.com/search?q=S
peed+Gearbox&source=lnms&tbm=is
ch&sa=X&ved=2ahUKEwj-
zMT54OfyAhVUeXAKHSfjDKIQ_AUo
AXoECAEQAw&biw=960&bih=468&d
pr=2
21
6.1 Introduction
Non metallic Gears
Spur Gears Bevel Gears Worm Gears
22
PGS.TS Nguyễn Hữu Lộc Racks Flexible Racks
6.1 Introduction
23
6.1 Introduction
Bánh răng hành tinh - Epicyclic 24

6.1 Introduction
25
6.1 Introduction
Among the gear transmissions listed below

1) Straight spur gear.
2) Bevel gear.
3) Herringbone gear.
4) Helical spur gear
5) Straight bevel gear.
6) Arc-toothed bevel gear.
7) Spiral bevel gear.
8) Helical bevel gear.
9) Racks and pinion
How many of the above transmissions are used to transmit
rotational motion between two intersecting axes? 26
6.1 Introduction
Manufacturing gears
Gears can be manufactured by a variety of
processes, including casting, forging,
extrusion, powder metallurgy, and blanking.
Of these, machining is the most common
manufacturing method used. Gear machining is
further classified into two categories: gear
generating and gear form-cutting
27
6.1 Introduction
Ring Gear Manufacturing Process
28
(Hand book of Mechanical Engineering)

29
30
31
32
https://en.wikipedia.org/wiki/List_of_gear_nomenclature
• Module m
• Pitch of the rack p
• Pressure angle
33
34
35
Exercise 6.1
2. The total depth in the

gear is 9mm (gear does
not correction). What
will the gear module
be?
1. 2 mm.
2. 2,5 mm.
3. 3 mm.
4. 4 mm.
36
Exercise 6.2 The spur gear drive has a modulus m = 10 mm, number of teeth z1 = 18 and z2 =
47. The gears do not correction. Calculate the geometry parameters in the case of internal and
external toothing .
37
Exercise 6.3
38
Exercise 6.4 What is the number of teeth z of the spur gear drive so
that the base diameter db is smaller than the root diameter df if the
dedendum hf = 1.25 m where m – module).
39
Process of load transmission
40
Contact between gear teeth:

(a) two pairs engagement
(b) one pair engagement.
41
6.3 Forces acting
bw on gears and shafts
Fn /2 bw
2’
2’
2
pb
2 Fn
W
g
1’ 1’
g
pb
b
1
pbt
a) Straight Spur gear; b) Load on the
process of mating; c) Helical Spur Gear
Sliding on the process of mating

42
Forces acting on a spur gear mesh
43
Forces acting on a helical gear mesh
44
Forces acting on a helical gear mesh
45
46
1 1 1 1
Fa
Fa
Ft Ft Ft Ft
Fa
a) b) c) d) Fa
When determining the direction of the force, we need to pay attention to:
- The direction of the peripheral force Ft : on the driving wheel Ft is always
in the opposite direction of rotation, on the driven wheel Ft in the same
direction of rotation.
- The direction of the axial force Fa depends on the direction of rotation, the
direction of the tooth face and the gear is driving or driven, but it is always
directed towards the tooth face.
- The direction of Fr is always towards the shaft's centerline.
47
6.3 Forces acting on gears and shafts Exercise 6.5
Exercise 5.25 Determine the
direction and value of the
forces acting on the gear pairs
according to the diagram in
Figure 5.8. Given the following
data in advance: T1 = 80 Nm, z1
= 20, z2 = 40, z3 = 18, z4 = 54
(on figure 5.8a then z1 = z3 và
z2 = z4). The modulus of all
gear pairs is the same m = 4
mm (for bevel gears me = 4
mm). Helix angle: herringbone
V gear is 30o, helical gears is
10o. The pressure angle of gear
pairs  = 20o.
48
6.10 Exercise
49
Exercise 6.6
Determine the direction of the forces acting on the transmission system
50
Exercise 6.7
Determine the direction of the forces acting on the transmission system
51
6.4 Calculated factors and efficiency of gear drives
(Handbook of Mech. Eng. 345-347 p)

52
Factor FHβ - Load distribution Uneveness along the contact line
K
53
54
Dynamic (Impact) loads Factor KV
55
Dynamic (Impact) loads Factor KV for straight spur gear
56
Dynamic (Impact) loads Factor KV for helical spur gear
57
The unevenness of the load distribution between the teeth (Factor KHα)
depends on production error (pith error and teeth direction)
For straight spur gear KHα = 1;
For helical spur gear KHα is determined
by formula:
4  (   1)(nacc  5)
KF =
4 
- The front contact ratio 

58
Failure Modes in Gears

Any failure to the gear
system leads to the total
system failure. Now let us
look into the various modes
by which the gears fail”
• Failures due to Scuffing
• Shock Loading Failures
• Fatigue Failures
• Failures due to Wear
For every tooth, stress

change in time according to
zero-to-tension stress
cycle, with is the cause of
fatigue damage
59
Fn
Pitting: This is a major
cause of gear failure 1
1
1 1
accounting for nearly
Hmax
FS2 FS1
60% of the gear
failures. Pitting is the
formation of craters on 2
b
the gear tooth surface. b)
2 d)
2
These craters are
formed due to the high FS1
FS2
amount of compressive 2
contact stresses in the

gear surface occurring a) Fn c) e)
during transmission of
the torque
60
Visually, micro pitting is not
so clearly visible at the first
go. One has to study the
surface of the gear tooth to
identify the micro pitting.
They appear as very small
dots which one can feel
when he runs his finger over
the gear tooth.
This sort of pitting normally tends

to make the gear useless and
damages the whole gear system.
61
Bending failure: Gear tooth behaves like a cantilever beam subjected to
repetitive bending stress. The tooth may crack due to repetitive bending stress
To avoid such failure, the module and face width of the gear is adjusted so that
the beam strength is greater than the dynamic load.
62
Wear is one of the common causes of failure we
know. During the course of operation anything FAILURES DUE TO WEAR
and everything tends to wear out starting from 1. Moderate Wear
the Tyres of the automobile to the joints in our 2. Abrasive Wear
body. Wear has hence not left our gears. 3. Corrosive Wear
63
64
65
1 1
Factor c
66
c=1 c=3
PGS.TS Nguyễn Hữu Lộc c=2
Allowable contact stresses for checked calculation:
K HL Z R ZV K l K xH
[H] = 0Hlim
sH
Allowable bending stresses:

OF lim KF C
[F] = KFL 67
PGS.TS Nguyễn Hữu Lộc sF
Kl - factor taking into account the influence of lubrication conditions,

normally Kl = 1.
KxH - factor taking into account the effect of gear size
KFC - factor taking into account the effect of two-way rotation on fatigue
strength; KFC = 1 for one-way rotation, KFC = 0.7 0.8 for two-way
rotation
68
69
70
71
Contact stress
72
Contact stress
73
Formula Hetz:
qn
 H = ZM

Elasticity factor that takes into account gear material properties
(modulus of elasticity and Poisson’s ratio):
E1 E2
ZM =
[ E2 (1  12 )  E1 (1  22 )]
74
75
76
ZH is a factor taking into account the shape of the contact surface:
Factor taking into account the effect of total contact length (Contact ratio
factor)
From here we have:
77
Center distance a:
For non-standard reducers, aw can be selected in the range R40: 80; 85; 90; 95; 100;
105; 110; 120; 125; 130 and about 10 if d <= 260 and about 20 when d <= 420,...
78
79
Bending stress
80
81
Bending stress
From this, the formula for designing gears according to bending stress
derived:
82
- Well lubricated gear drive – Contact strength
+ Check Calculation
H] is allowable contact stress; KH is load or calculated factor

+ Design Calculation
- Non lubricated gear drive – Bending (Beam) strength

+ Check Calculation
+ Design Calculation
83
Exercise 6.8
Which formula is correct?
84
Exercise 6.9
85
6.10.3 Calculation sequence of spur gear transmission

Parameters given: power P1 (or torque T1), number of revolutions n1
and gear ratio u.
Design procedure :
1- Select gear material, heat treatment method, material mechanical
properties such as strength limit, yield limit, hardness (fatigue limit
inferred).
2- Determine the allowable contact stress [H] and bending stress [F]
for preliminary design according to the formulas (6.33) and (6.47).
Determining the calculation criteria is according to the contact stress or
bending stress depending on the lubrication, the surface hardness of
the material,...
If the design is calculated according to the contact stress, we continue
to calculate in the following order:
3- Select the allowable contact stress [H] according to the driven gear,
which is the gear with lower strength.
86
4- Select the gear width factor ba according to the standard (page 259
and table 6.15). Calculate bd and preliminarily select the load factor to
calculate KH = KH according to table 6.4.
5- Calculate the center distance aw according to the formula (6.67). For
the reducer, we choose the standard center distance.
6- Depending on the surface hardness, we choose the module m
according to the center distance aw (formula 6.68 - 6.70) and choose m
according to the standard set value. The smaller the modulus, the larger
the number of teeth, thereby increasing the anti-sticking ability,
increasing the face contact ratio, reducing noise and cutting labor,
reducing material waste (reducing the tip diameter), but the bending
strength is reduced.
7- Determine the total number of teeth according to the formula (6.71),
then determine the number of teeth z1 and z2.
8- Recalculate gear speed ratio u. When necessary, check the error u
 2  4%.
87
9- Determine the geometry parameters of gear drive . Diameter

values are accurate to 0.01mm.
10- Calculate the peripheral speed v and select the grade of accuracy
Table 6.3.
11- Determine the value of the forces acting on the gear mesh.
12- Select dynamic load factors KHV and KFV according to tables 6.5,
6.6.
13- Determine the calculated stress H on the contact area according
to the formula (6.63). Overload up to 5% is allowed. If the contact
strength condition is not satisfied, we increase the width of the tooth b2.
If this is not satisfactory, change the distance aw or choose a material
with higher strength and recalculate.
14- According to the formula (6.80) calculate the coefficients and and
determine the comparative bending strength according to the ratio
[F]/YF. Test calculations are carried out on gears with lower strength.
15- Calculate the value of bending stress at the tooth bottom according
to the formula (6.78).
88
6.8 Design and analysis of helical spur gear
Helical spur gear
89
Heringbone Gear
90
91
92
93
Calculation of helical spur gear
https://egyankosh.ac.in/bitstream/123456789/31615/1/Unit-11.pdf
94
Calculation of helical spur gear
95
The equivalent pitch diameter:
The equivalent number of teeth:
Reply and
We have formula:
96
97
Formula Hetz:
qn
 H = ZM

Elasticity factor that takes into account gear material properties
(modulus of elasticity and Poisson’s ratio):
E1 E2
ZM =
[ E2 (1  12 )  E1 (1  22 )]
ZH is a factor taking into account the shape of the contact surface:
Factor taking into account the effect of total contact length

(Contact ratio factor)
From here we have:
98
Rolling circle diameter of pinion (driving gear) dw1:
Reply: and
We have formula for center distance:
or:
Select the standard value of the module m according to the axis

distance a, similar to the spur gear
99
Bending stress
From this, the formula for designing gears according to bending stress
derived:
Helix angle:
20o    8o for helical spur gear
and
40o    30o for herringbone gear
100
6.9 Bevel gear drive
101
102
Straight bevel gear
103
Helical bevel gear
104
Spiral bevel gear
105
Manufacturing of bevel gear
106
Geometry of bevel gear
107
108
The everage pitch diameter:
The shaft angle:

The pitch angle of driving gear (pinion):
The outside and average cone distance:
109
110
6.9 Bevel gear drive 2
T2
Forces acting
on gear mesh
Ft2
Fr2 Fa2
d m1 Fr1 = Ft1 tan  cos 1
Fa1 = Ft1 tan  sin 1

1
Fr1
w
Fa1 F t1
T1
1
1
Fn1
111
112
Exercise
Forces acting on
the gear drives
113
114

The diameter of the equivalent spur gear are:
The equivalent number of teeth:
The equivalent speed ratio:
115
Design of bevel gear
Design calculation by contact strength:
qmax
2
b b/
b
Re b /2
qm
qmin
dm1
The equivalent radius of curvaturede1
1 1 1 2 2
   
 1 2 dv1 sin  dv2 sin 
1 2 u2  1

 dm1 sin  u
116
Load per 1 mm normal to the surface:
We obtain the calculation equation:

2T1 .103 K H u2  1
 H  Z H ZM Z  [ H ]
2
0, 85dm 1bu
Design equation for the average pith diameter:
Reply:
We have:
117
118
Bending strengh of bevel gear
Check calculation:
Design calculation:
From this we can determine:
119
Calculation of bevel gear transmission is similar to spur

gear, but only the modulus calculation steps are different.
120
Exercise 6.4. Design calculation of the spur gear drive in the reducer
of the transmission system for the conveyor in Figure 3.1. The data is
given in Table 3.5. Service life: Lh = 8000h
121

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Chapter 6 Gear drives

A gear drive has three main

Straight spur Helical spur gear Bevel gear

Screw gear - Crossed helical gear (trụ xoắn)

Spiral bevel Hypoid 9

Gear wheel. Mechanical transmission system. Silhouette vector

An epicycloid is formed when a circle rolls on the outside of a base circle.

Hypocycloid is formed when a circle rolls on the inside of a base circle.

Bánh răng cicloid

Spur gear Helical gear

Applications of gear drive

Typical watch escapement and gear train

Spur Gears Bevel Gears Worm Gears

Bánh răng hành tinh - Epicyclic 24

Among the gear transmissions listed below

(Hand book of Mechanical Engineering)

2. The total depth in the

Process of load transmission

Contact between gear teeth:

Sliding on the process of mating

Forces acting on a helical gear mesh

Determine the direction of the forces acting on the transmission system

(Handbook of Mech. Eng. 345-347 p)

Dynamic (Impact) loads Factor KV for straight spur gear

- The front contact ratio 

Failure Modes in Gears

For every tooth, stress

contact stresses in the

This sort of pitting normally tends

Allowable bending stresses:

Kl - factor taking into account the influence of lubrication conditions,

ZH is a factor taking into account the shape of the contact surface:

From here we have:

H] is allowable contact stress; KH is load or calculated factor

- Non lubricated gear drive – Bending (Beam) strength

Which formula is correct?

6.10.3 Calculation sequence of spur gear transmission

9- Determine the geometry parameters of gear drive . Diameter

Helical spur gear

Calculation of helical spur gear

The equivalent number of teeth:

Factor taking into account the effect of total contact length

From here we have:

We have formula for center distance:

Select the standard value of the module m according to the axis

Manufacturing of bevel gear

Geometry of bevel gear

The shaft angle:

The outside and average cone distance:

Fa1 = Ft1 tan  sin 1

PGS.TS Nguyễn Hữu Lộc

The diameter of the equivalent spur gear are:

The equivalent number of teeth:

The equivalent speed ratio:

We obtain the calculation equation:

Bending strengh of bevel gear

From this we can determine:

Calculation of bevel gear transmission is similar to spur

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