Design Engineering: Power and Motion

Transmission Devices

Power Transmission:
o From prime mover to machine
o From one shaft to another
 Transmission of motion or power from one shaft
Gear Drives to another by means of direct contact

A gear is a wheel with teeth on its outer/inner edge

The teeth of one gear mesh (or engage) with the teeth of another

Why:
o Compact layout
o Can transmit very large power
o Change the axis of the motion

Applications:
•Packaging machine
•Food processing machine
•Car production machine
•Machine tool industry
•Automatic cutting / welding machine
•Machine for medical/cosmetic field
•Construction machine
•Wood / Glass processing machine, Agricultural machinery
 Gear drives Fundamentals
o Transmit the power by direct contact

o The surface of two body make a tangential contact

o No motion is possible along the common normal

o Capable of changing the amount of power and torque (Example: high speed car and Tractor)

o Modifying the axis of rotation

o Changing the speed of rotation, high velocity reduction (compound drive)

o Positive drive (no slip and creep)

o Gear drive can not protect the system from impact and overloading (vibration and slip in belt drive)
o Can not tolerate small amount misalignment
o Lubrication and high cost.
 Frictional Wheel
o Power transmitted between two shaft is small

o Motion transferred by a plain cylinder or disc (Frictional wheel)

Velocity of Driven shaft

Velocity Ratio (VR) = Velocity of Driving Shaft

Linear velocity:
𝑟1 × 𝜔1 = 𝑟2 × 𝜔2 Frictional wheel

𝑁2 𝐷1
=
𝑁1 𝐷2

o Increase in load, slip increases, Gear required

✓ The disc with teeth is known as gear.

✓ The motion between the surfaces changes from rolling/sliding
✓ Two meshed gears always rotate in opposite directions
Gear dive
 Gear Terminology
Pitch point:
o Point at which two teeth meet (no line contact, no
surface contact)
o Less contact, less friction and less power losses.

Pitch Circle:

o Locus of all the pitch point is called a pitch circle

o The pitch circle of a gear corresponds to the outer

circumference of the friction wheel

Pitch diameter: Diameter of a pitch circle

 Gear Terminology
Circular pitch:
➢ Distance measured along the circumference of the pitch circle, from a point of one tooth to the corresponding
point on the adjacent tooth.

𝜋𝑑 p = circular pitch
𝑝= d = pitch diameter
𝑇
T = number of teeth

➢ Meshing gears must have the same circular pitch

Diametral pitch:
➢ Number of teeth per unit length of the pitch circle diameter
𝑇
𝑃=
𝑑
𝜋𝑑 𝑇
𝑝×𝑃 = × = 𝜋
𝑇 𝑑 Pitch Angle (γ): The angle subtracted by the circular pitch at
centre of the pitch circle
➢ Meshing gears must have the same diametral pitch
 Gear Terminology
Module:
➢ Pitch Circle is an imaginary circle that can’t measure practically to Pitch

circle diameter.
𝜋𝑑
➢ Pitch (p) = is not use for the gear procurement.
𝑇
𝑝 𝑑
➢ Module (m) = =
𝜋 𝑇

✓ It is the ratio of the pitch diameter (mm) to the number of teeth

➢ Module determines the overall size of a gear.

✓ Gears will only mesh with each other if they have teeth of the same module.
 Gear Terminology
Addendum Circle:
o Circle joining all the top surfaces

Addendum:
o Radial height of the tooth above the pitch circle
o Standard value is one module (m)

Dedendum (root) Circle:

o Circle passing through the roots of the teeth

Dedendum:
o Radial depth of the tooth below the pitch circle
o Standard value is 1.25m

Face: Tooth surface between the pitch circle and top land

Flank: Tooth surface between the pitch circle and bottom land
 Gear Terminology
Clearance:
o The distance between the outside circle of a gear and the root
circle of its mating gear (the gap) is called the root clearance.

o It compensates for thermal expansion

• Addendum = 1m

• Dedendum = 1.25 m

• Clearance = 0.25 m
 Gear Terminology
Whole depth:

o The total depth of the space between adjacent teeth and

is equal to addendum plus dedendum

• whole depth = 1m + 1.25m = 2.25 m

Working depth of the teeth:

o The maximum depth to which a tooth penetrates in to the tooth
space of the mating gears

o Sum of the addendum of the two gears = 2m

 Gear Terminology
How to determine Module :

𝑑
Module (m) =
𝑇

Pitch circle diameter (d) = ????

Total teeth length = whole depth = 1.25m Module (mm)

0.5
𝑡𝑒𝑒𝑡ℎ 𝑙𝑒𝑛𝑔𝑡ℎ 0.75
𝑚𝑜𝑑𝑢𝑙𝑒 𝑚 =
1.25 1
1.25
1.5
1.75
2
 Gear Terminology
Point of Contact:
➢ A point of contact is any point at which two tooth profiles touch
each other
Line of Contact (pressure line):

➢ The force excreted by the driver tooth to the driven tooth

is along a pitch point to the point of contact of two teeth.
➢ First point of contact is called the initial point and is
always on the addendum circle of the driven gear.
Driver
➢ Final point of contact which is always on the addendum
circle of the driving gear.
➢ This create a line which goes through the pitch point, is
the line of action.
➢ A line normal to a pair of mating tooth profiles at their
Driven
point of contact
 Gear Terminology
Path of Contact or contact length :

➢ The locus of point of contact of two mating teeth from beginning of

engagement to the end of the engagement

➢ The length from the start of the tooth contact to the end of contact is
called the length of action

o Path of approach: portion of path of contact from beginning of

engagement to the pitch point (length CP)

o Path of Recess: portion of path of contact from pitch point to the end of
the engagement (length PD)

Pressure Angle:
➢ The angle between the pressure line and the common tangent to the pitch
circle
 Gear Terminology
Arc of contact:
➢ The locus of a point on the pitch circle from the beginning to the end of the
engagement of two meting gears (APB or EPF)

o AP/EP = arc of approaches

o PB/PF = arc of recess

Angle of action:
➢ Angle turned by the gear (pitch circle) from the beginning of
engagement to the end of engagement

o Angle of action (δ) = angle of approach (α)+ angle of recess (β)

Contact Ratio: Angle of action divided by pitch angle

or
o Ratio of arc of contact to the circular pitch

𝛿 𝛼+𝛽 𝐴𝑟𝑐 𝑜𝑓 𝑐𝑜𝑛𝑡𝑎𝑐𝑡

Contact Ratio = 𝛾 = Contact Ratio=
𝛾 𝐶𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑝𝑖𝑡𝑐ℎ
 Gear Terminology
Gear ratio:
➢ It is ratio of the number of the teeth on the gear to that on the pinion
𝑇1
𝐺=
𝑇2

Velocity ratio:

o Speed ratio (or velocity ratio) of gear train is the ratio of the speed of the follower (driven) gear to the speed of the
driver gear

𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑜𝑙𝑙𝑜𝑤𝑒𝑟

𝑉𝑅 =
𝐴𝑛𝑔𝑢𝑙𝑎𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑑𝑟𝑖𝑣𝑒𝑟

𝜔2 𝑁2
𝑉𝑅 = = &
𝜔1 𝑁1
𝑁2 𝑑1 𝑑1 𝑇1
𝑁2 𝑑1 𝑇1
= 𝑉𝑅 = = =
𝑁1 𝑑2 & = (constant pitch) 𝑁1 𝑑2 𝑇2
𝑑2 𝑇2
 Law of Gearing
➢ The law of gearing states that the angular velocity ratio between
the gears of a gear set must remain constant throughout the mesh.

o Point C of gear 1 in contact with point D of gear 2

o Must have a common normal at point (n - n)

o Linear velocity of point C = 𝑣𝑐 = 𝜔1 𝐴𝐶

o Linear velocity of point D = 𝑣𝑑 = 𝜔2 𝐵𝐷 Body 1 and 2 represent portion of two gears in mesh

o Relative motion between the surface along the common normal must zero to
avoid separation and penetration

Relative motion along the n-n

 Law of Gearing

△ BFP and EAP are similar

o Centre line AB is divided at P by common normal in inverse ratio of

angular velocity
o For the constant angular velocity ratio, the common normal at point of
contact should pass through a fixed point (P)
o The point P divides the centre line in the reverse ratio angular velocities
of two gears

• Law of gearing states that the common normal at the point of contact between a pair of teeth must always
pass through the pitch point for all positions of mating gear
 Velocity of Sliding
➢ Curved surface of the two teeth of the gears (1 and 2) are to remain in
the contact
➢ One can have a relative motion to the other along the common tangent

Component of 𝑣𝑐 along t-t = 𝑣𝑐 𝑠𝑖𝑛𝛼

Component of 𝑣𝑐 along t-t = 𝑣𝑑 𝑠𝑖𝑛𝛽

Velocity of sliding = 𝑣𝑐 𝑠𝑖𝑛𝛼 − 𝑣𝑑 𝑠𝑖𝑛𝛽

Velocity of sliding = sum of angular velocities X distance

between the pitch point and point of contact
o C and d are the coinciding points
 Gear Teeth Profile
o Smooth and noiseless power transmission

o Constant torque power transmission

o Must follow the law of gearing: the common normal at point of contact of

two mating profiles of the teeth must pass through a fixed point which is

also a pitch point

Standard from of teeth profile

o Involute profile teeth

o Cycloidal profile teeth

 Involute Profile Teeth Fundamentals

F
F Torque (T1) = 𝐹 × 𝑟1 F
r3 r2 F F
r1 Torque (T2) = 𝐹 × 𝑟2 F
Torque (T3) = 𝐹 × 𝑟3

T3 > T2 > T1

Torque T1 = T2 = T3
 Involute Profile Teeth
Involute teeth Profile:
o Locus of point on the straight line which rolls without slipping on the circumference of a circle

o Path traced out by the end of a piece of taut cord being unwound from the
circumference of circle
o Path traced out by the point A is called involute

o Base Circle: The circle on which the straight line rolls of from which the cord is
unwound is known as the base circle

o Line bB, cC, dD, eE is tangent to the base circle. Hence normal to the involute
is a tangent to the base circle.
 Cycloidal Profile Teeth
Cycloid:

o A curve generated by a point on the circumference of a circle which moves along a straight line

Cycloid

Circle

Straight line

https://www.youtube.com/watch?v=x0Z9OeJbRy4
 Cycloidal Profile Teeth
Epicycloid:

o Locus of a point on the circumference of circle that rolls

without slipping on the circumference of a another circle

Hypocycloid:

o Locus of a point on the circumference of circle that rolls

without slipping inside the circumference of a another circle

Cycloidal = Epicycloid + Hypocycloid

(face) (flank)
 Comparison of the Cycloidal and involute Profile Teeth
Cycloidal Teeth Involute Teeth

1) Constant Pressure angle

1) Pressure angle varies
2) Involves single curve for the teeth resulting in easier
2) Involves double curves for the teeth, complicates
manufacturing
manufacturing process
3) Cheaper
3) Costlier
4) A little variation in centre distance does not affect the
4) Exact centre distance is required to transmit a
velocity ratio
constant velocity ratio
 Types of Gears
➢ According the relative positions of shaft axes, 3 different types of gears are used.

1. Parallel Shaft

2. Intersecting Shafts

3. Skew Shafts
Parallel Shaft

Intersecting Shafts
Skew Shaft