ME306: ENGINEERING DESIGN

Gears
Presented Eng T Chikuku

I acknowledge the contribution to this slide to the class of 2016 part 3

Kurebwa Joseph G. Duri Kudzanai Solomon Rutendo F.

Virukayi Tanyaradzwa Ncube Bandile Mombeyarara Panashe A.
Gear Classification &
Applications
Gear Classification
Gears or toothed wheels may be classified as
follows :
1. According to the peripheral velocity of the gears.
2. According to the type of gearing.
3. According to the position of teeth on the gear.
4. According to the position of axes of the shafts.
Gear Classification:
Peripheral Velocity
The gears, according to the peripheral velocity of the gears,
may be classified as :
(a) Low velocity,
(b) Medium velocity, and
(c) High velocity.
Gears having velocity less than 3 m/s are termed as low
velocity gears and gears having velocity between 3 and
15 m/s are known as medium velocity gears. If the
velocity of gears is more than 15 m/s, then these are
called high speed gears.
Gear Classification:
Type of gearing
The gears, according to the type of gearing, may be
classified as :
(a) External gearing,
(b) Internal gearing, and
(c) Rack and pinion.
Gear Classification:
Position of teeth
The teeth on the gear surface may be
(a) Straight,
(b) Inclined, and
(c) Curved.
We have discussed earlier that the spur gears have straight teeth
whereas helical gears have their teeth inclined to the wheel rim. In
case of spiral gears, the teeth are curved over the rim surface.
Gear Classification:
Parallel Shafts

Helical Spur

Herringbone Helical
Gear Classification:
Intersecting Shafts

Straight Bevel Spiral Bevel

Gear Classification:
Skew Shafts

Worm Hypoid
 Why use gears?
We have discussed earlier that the slipping of a belt or rope is a
common phenomenon in the transmission of motion or power between
two shafts. The effect of slipping is to reduce the velocity ratio of the
system. In precision machines, in which a definite velocity ratio is of
importance (as in watch mechanism), the only positive drive is by
gears or toothed wheels.
Why use gears?
Advantages of a gear drive over other drives
i.e. Belt, Chain & Rope Drives

1. It transmits exact velocity ratio.

2. It may be used to transmit large power.
3. It may be used for small centre distances of
shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Why use gears?
Disadvantages of gear drives compared to
other drives
1. Since the manufacture of gears require special
tools and equipment, therefore they are is costlier
than other drives.
2. The error in cutting teeth may cause vibrations
and noise during operation.
3. Require suitable lubricant and reliable method of
applying it, for the proper operation of gear drives.
Spur Gears
Spur gears or straight-cut gears are the simplest type of
gear. They consist of a cylinder or disk with teeth projecting
radially. Though the teeth are not straight-sided (but usually
of special form to achieve a constant drive ratio, mainly
involute but less commonly cycloidal), the edge of each
tooth is straight and aligned parallel to the axis of rotation.
Why are spur gears noisy at high speeds?
These gears mesh together correctly only if fitted to parallel
shafts. No axial thrust is created by the tooth loads. Spur
gears are excellent at moderate speeds but tend to be noisy
at high speeds.

I.C.E. Aircraft turbine Control System

 Parallel Helical Gears
Helical gears are used for parallel shaft drives. They have teeth
inclined to the axis as shown in previous slides. Hence for the
same width, their teeth are longer than spur gears and have
higher load carrying capacity. Their contact ratio is higher than
spur gears and they operate smoother and quieter than spur
gears. Their precision rating is good. Helical gears are therefore
Why
usedareforhelical gearsapplication
high-speed less efficient than spur
with rotational gears
speed of the
above
3600 rpm or with pitch linesame
velocity above 1500 m/min and large
size?
power transmissions. They are used where noise control is
important. Their efficiency is slightly lower than spur gears and
the helix angle introduces axial thrust on the shaft. Thus, these
gears find wide applications in automotive gearboxes as
illustrated.
Parallel helical gears are invariably used in drawing machines to drive the drafting rollers and
coiler rollers as they rotate at very high speeds. They are also used on the back bottom drafting
rollers of roving and ring spinning machines.
 Crossed Helical Gears
The gear trains transmit motion from calender rollers to coiler rollers that
deposit the sliver into the can of card. A pair of crossed helical gears is
shown below. The two meshing gears on the left side are crossed helical
gears of left hand. The bottom crossed helical gear (driver) is compounded to
a spur gear mounted on the shaft of bottom calender roller. The shaft of
driven crossed helical gear (top) is inclined to the driving shaft (bottom). Both
the crossed helical gears are mounted on non-parallel and non-intersecting
shafts. Since the can (sliver container) must be placed near the operator
(away from the calender rollers) for easy handling, this arrangement is
required.
 Double Helical Gears
Double helical or Herringbone gears used for transmitting power
between two parallel shafts. They have opposing helical teeth with or
without a gap depending on the manufacturing method adopted. Two
axial thrusts oppose each other and nullify. Hence the shaft is free
from any axial force. Though their load capacity is very high,
manufacturing difficulty makes them costlier than single helical gear.
Their applications are limited to high capacity reduction drives like that
of cement mills and crushers, one such application is exhibited here.
Double Helical Gears

Their applications are limited to high capacity

reduction drives like that of cement mills and
crushers, one such application is exhibited here.
 Straight Bevel Gears
Straight bevel gears are used primarily for low speed application with pitch
line velocities up to 300 m/min. Their precision rating is fair to good. They
are suitable for 1:1 and higher velocity ratios and for right-angle meshes to
any other angles. Their good choice is for right angle drive of particularly low
ratios. However, complicated both form and fabrication limits achievement of
precision. They should be located at one of the less critical meshes of the
train. They are widely used in textile machines and automotive differentials.
Few of applications are listed below:
• drive to bobbin rail on roving machine,
• drive between the doffer and feed roller on low speed carding machines,
• drive from calender roller to coiler rollers, top coiler to bottom coiler
plates in card, comber and drawing machine, and
• drive between calender roll and lap stop mechanism-lever in lap former
of conventional blow room.
 Straight Bevel Gears
A typical application of straight bevel used in differential application is
shown here.
 Spiral Bevel Gears
Spiral bevel gears shown below are also used for transmitting power
between intersecting shafts. Because of the spiral tooth, the contact
length is more and contact ratio is more. They operate smoother than
straight bevel gears and have higher load capacity. But, their
efficiency is slightly lower than straight bevel gear. Usage of spiral
bevel gears in an automobile differential is shown.
GEAR CONSIDERATIONS & MATERIALS
CONSIDERATIONS

3.Centre to
1.Power
2.Velocity
distance
ratio:
be
transmitted
Vg/Vd=Tg/Td
(in mm) (KW)
 REQUIREMENTS
 The following requirements must be met in the design of a gear
drive :
 (a) The gear teeth should have sufficient strength so that they will
not fail under static loading or dynamic loading during normal
running conditions
 (b) The gear teeth should have wear characteristics for long
lifetime
 (c) The use of space and material should be economical.
 (d) The alignment of the gears and deflections of the shafts must be
considered because they effect on the performance of gears
 (e) The lubrication of the gears must be satisfactory
A summary of
requirements

Wear
properties Lubricatio
n

Strength

Requirements to
be met in design

Space &
material

Alignment
 GEAR MATERIALS

“Imagine if a human being was made of metal how many bolts, nuts and washers one would
have, but nature always gives us examples why we should be particular on choosing materials”

Basically, the material used for the manufacture of gears depends on application
 SELECTION OF MATERIAL

The gear material should have the following properties

 high tensile strength to prevent failure against static loads

 High endurance strength to withstand dynamic loads

 Low coefficient of friction

 Good manufacturability
 Cont…
 The gears are manufactured either from metallic or non-metallic materials.

 The metallic gears with cut teeth are commercially obtainable in cast iron, steel
and bronze

 Cast iron is widely used for the manufacture of gears due to its good wearing
properties, excellent machinability and ease of producing complicated shapes by
casting method.

 Cast iron gears with cut teeth may be employed, where smooth action is not
important.
 Cont...

 Steel is used for high strength gears and steel may be plain carbon
steel or alloy steel.
 The steel gears are usually heat treated in order to combine
properly the toughness and tooth hardness.
 Phosphor bronze is widely used for worm gears in order to reduce
wear of the worms which will be excessive with cast iron or steel.
 The non-metallic materials like wood, compressed paper and
synthetic resins like nylon are used for gears, especially for
reducing noise
 Cont…advantages of non metallic materials (plastics)
.
 Whenever food is being packaged or prepared, clean and sterilisable surfaces and vessels
are critical
 Plastics can be heated or cooled repeatedly without affecting food taste or appearance
 Food preparation equipment made with plastics can be frequently disinfected and sterilized
without fear of degradation.
 Bearing or load surfaces made from plastics will not introduce dangerous shavings and
require no lubrication.
 And plastics can be machined, molded, or formed into almost any shape imaginable
 plastic gears are much more economical to produce and allow the manufacturer to provide
a product at a lower cost to the customer.
 A plastic gear will tolerate dirt and debris much better than a metal gear. Metal gears tent
to grind and pulverize a dirt particle while a plastic gear tends to absorb the dirt particle.
 Most machines used in an office setting use a series of plastic gears to allow the machine
to operate at a substantial noise reduction
 Cont…

 NB: heated treated materials have a higher allowable static stress and non
metallic materials have relative low allowable stress
 Cont…Examples
 (a) Wood (b) Plastic (c) rawhide

 (d) cast iron (e) cast steel (f) phosphor bronze

TYPES OF GEAR FAILURE

SCORING
 welding and tearing action resulting from metallic contact removes the metal rapidly and continuously .
SCORING
Causes
 lubrication failure in the contact region
 establishment of metal to metal contact.
SOLUTION
 This type of failure can be avoided by properly designing the parameters such as speed and pressure
 proper flow of the lubricant, so that the temperature at the rubbing faces is within the permissible limits.
 •Take the cooling system of lubricating oil into consideration, to reduce the temperature rise of lubricating oil.
 •It may happen in conditions that the load is over large, and the oil temperature is too high, and there is abnormal temperature
rise, and incomplete cooling.
 Use anti scuffing additives
 STAGES OF SCORING
INITIAL SCORING
 Initial scoring occurs at the high spots left by previous machining. Lubrication failure at these
spots leads to initial scoring or scuffing.The scoring will then stop if the load, speed and
temperature of oil remain unchanged or reduced
 It is non progressive and corrective
MODERATE SCORING
 After initial scoring if the load, speed or oil temperature increases, the scoring will spread over to a larger area. The Scoring
progresses at tolerable rate. This is called moderate scoring