Machine design ME322

Course-2-0-2

Week-1 Lecture-1 Introduction

Course Instructor: Dr. Poonam Kumari

Associate Professor
Department of Mechanical Engineering
IIT Guwahati, Guwahati-781039
 L-T-P- 2-0-2
Course:
Module -1 -Design of Gears;

Module 2- Lubrication and Wear consideration in Design; Design and selection of

Bearings: Hydrodynamic lubrication theory, Hydrostatic and Hydrodynamic bearings
(e.g., journal), Rolling Element Bearings;

Module -3 Systems Approach to Design: Decision Making, Simulation of mechanical

systems using CAD tools, Sensitivity analysis of design parameters, Value Analysis
and Value Addition to designed components and systems;

Module -4 Exercises of mechanical systems design with examples; Overview of

Optimization in Design; Reliability and Robust Design; Communicating the Design.

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Texts:
[1] Design Data Book of Engineers, Compiled by Faculty of Mechanical Engineering, PSG College of
Technology, Publisher Kalaikathir Achchagam, Coimbataore, 2009
[2] J. E. Shigley, Mechanical Engineering Design, McGraw Hill, 1989

References:
[1] G. M. Maitra Handbook of gear Design Second Edition, Tata McGraw Hill, New Delhi, 1994.
[2] D.W. Dudley, Handbook of Practical Gear Design, CRC Press, 2009
[3] M.F. Spotts, T.E. Shoup, L. E. Hornberger, S. R Jayram and C. V. Venkatesh, Design of Machine Elements,
8th Ed., Person Education, 2006.
[4] V. B. Bhandari, Design of Machine Elements, 2nd Ed., Tata Mcgraw Hill, 2007.
[5] R. C. Juvinall and K. M Marshek, Fundamentals of Machine Component Design, 3rd Ed., Wiley, 2007.
[6] V. Ramamurti, Computer Aided Mechanical Design and Analysis, 3rd Ed., Tata McGraw Hill, 1996.
[7] A. H. Burr and J. B. Cheatham, Mechanical Analysis and Design, 2nd Ed., Prentice Hall, 1997.
[8] J. R. Dixon, Design Engineering: Inventiveness, Analysis and Decision Making, TMH, New Delhi, 1980.

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Evaluation Scheme
• Project 30%
Assignments 10%
quizzes 15%
Midsem 20 %
End sem Exam 25%

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 The design project has to be approved by the instructor.
Whatever project you select, your group must meet the following design phase deadlines and submit
with one page project summary at each stage:
1. Group Finalization: Date: Monday, January 16
2. Problem Finalization: Date: Monday, January 22
3. Background of the problem: Date: Monday, January 29
The background should identify the nature of the problem and clearly explain the need for the solution
you will design.

1. Project goal statement: Date: Monday, February 5

The goal statement should be precise and clear. After meeting with the instructor and getting his approval, you
may proceed to the next step of the design.

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 Module 1- GEARS

Lecture 1 - INTRODUCTION

https://nptel.ac.in/courses/112/106/112106137/

Machine Desig Mechanical Prof. M.M. IIT Madras Web

n II Engineering Mayuram
Prof. K.
Gopinath

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 Contents

• 1.1 History of gears

• 1.2 Definition of gears
• 1.3 Types of gears and their applications
• 1.4 Spur gear
• 1.5 Helical gear
• 1.6 Double helical or herringbone gears
• 1.7 Internal gear
• 1.8 Rack and Pinion
• 1.9 Bevel gear
• 1.10 Crossed helical gear
• a)Straight b)Spiral c)Hypoid
• 1.11 Law of gearing
• 1.12 Gear profiles
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• 1.13 Meshing of gears
1.1 HISTORY OF GEARS

• Indian history as per our mythological stories is more than 12,000 years old. Since then people
living here have been striving to improve the living conditions. We also know that earlier people
were living in the caves and the doors of the caves were made of granite. How were these heavy
doors opened and closed? They were opened and closed by none other than a system with gear
mechanism, wheel, lever and rope drives. However, the documented evidence has been lost due to
destruction by the invaders and improper storing of palm leaf literature.

• The guruKula method of teaching and passing of the information from mouth to ear procedure and
keeping some of the advances as closely guarded secret have resulted in poor dissemination of the
knowledge and documentation. But, the knowledge of gears has gone from India to east through
some of the globe trotters from China as back as 2600 years BC.
• They have used the gears then ingeniously in chariots for measuring the speed and other
mechanisms. Primitive gears shown in Fig. 1 were first used in door drive mechanism in temples
and caves, and water lifting mechanisms 2600 B.C. in India and elsewhere.

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• Aristotle in the fourth century B.C. mentions in his writings that gears were being used very
commonly in many applications. Classical origin of worm gearing was made by Archimedes 287-
212 B.C. Vitruvius a military engineer in his writing in 28 B.C. has described a number of gear
applications, typical ones are shown in Figs. 1.2 and 1.3.

Fig.1.1 Primitive gears made of wood

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Fig.1.2 Water wheel and grain mill described Fig.1.3 Schematic diagram of an odometer for a carriage
by Vitruvius 40 B.C described by Vitruvius 28 BC

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• Leonard da Vinci used multitudes of gears in various mechanisms developed by him 500 A.D.
Greek and Roman literatures show extensive usage of gears for forward motion. Toothed gears
used for the clocks of Cathedrals and other ecclesiastical buildings during the middle ages are still
preserved in many places. Salisbury cathedral still possesses the oldest clock in England made in
1386. The Wells Cathedral clock made in 1392 is preserved in Science museum, South
Kensington. Though the iron gears have worn out to some extent, they still keep good timings.
• German artist Albrecht Durer’s engravings show a vehicle
designed for the Emperor Maximilian I during 15th century
which is shown in Fig.1.4. That vehicle was driven by worm
gears on all four wheels. This clearly shows that he knew
the concept of gearing which helped him in sketching them
accurately.
• In 18th century, Industrial Revolution in England led to usage
of cycloidal gears for clocks, irrigation devices, water mills
and powered machines. Fig. 1.5 gives the glimpses of
their contribution to engine application.

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Fig.1.4 Chariot using worm gears
11
• The industrialization of west made a big impact on gear technology which is the key to the modern
development and the gear technology is advancing rapidly. It is most unlikely that gears are going
to be replaced by any other component for their function in the near future

Fig.1.5 Schematic diagram of Watt’s rotating Engine, 1784, first

24/04/2024 engine to produce power directly on a shaft 12
1.2 Definition of gears

• Gears are toothed members which transmit power / motion between two shafts by meshing
without any slip. Hence, gear drives are also called positive drives.

• The smaller one is called pinion and the larger one is called gear immaterial of which is driving the
other.

• When pinion is the driver, it results in step down drive in which the output speed decreases and the
torque increases. On the other hand, when the gear is the driver, it results in step up drive in which
the output speed increases and the torque decreases.

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1.3 Classification of gears

• Gears are classified according to the shape of the tooth pair and disposition into spur, helical,
double helical, straight bevel, spiral bevel and hypoid bevel, worm and spiral gears and this is
shown in Fig. 1.6

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1.4 Spur Gears
• They are simple in construction, easy to manufacture and cost less. They have highest efficiency
and excellent precision rating.
• They are used in high speed and high load application in all types of trains and a wide range of
velocity ratios. Hence, they find wide applications right from clocks, household gadgets, motor
cycles, automobiles, and railways to aircrafts.
Spur gears have their teeth parallel to the axis and are used for transmitting power
between two parallel shafts.
They are used in high speed and high load application in all types of trains and a
wide range of velocity ratios.

Hence, they find wide applications right from clocks, household gadgets, motor
cycles, automobiles, and railways to aircrafts.

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Fig.1.7 Spur Gear
15
1.5 HELICAL GEARS
• The teeth of a helical gear are set at an angle (relative to axis of the gear) and take the shape of a
helix. This allows the teeth to mesh gradually, starting as point contact and developing into line
contact as engagement progresses
• Helical gears are used for parallel shaft drives. Hence for the same width, their teeth are longer
than spur gears and have higher load carrying capacity.
• Higher contact ratio than spur gears
• Smoother and quieter operation, Thus, these gears find wide applications in automotive gearboxes.
• Their efficiency is slightly lower than spur gears. The helix angle also introduces axial thrust on
the shaft.

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 Advantage and applications of HELICAL GEARS
• Smooth operation is guaranteed due to the gradual engagement of the angled teeth of helical gears as
compared to those of spur gears.
• Helical gearboxes and helical gears are long lasting and most suited for applications involving high
loads.
• It is able to conduct power and motion between right angle or parallel shafts.
• Wear and tear is reduced due to load distribution between numerous teeth.

• Printing, earth-moving and fertilizer industries

• Port and power industries, steel and rolling mills
• Textile industries, food industries, plastic industries, elevators, conveyors,
compressors, blowers, cutters and oil industries

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1.6 DOUBLE HELICAL GEAR OR HERRINGBONE GEAR

• 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 as shown in figure.

Double Helical Gear or Herringbone

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Gear
 1.7 INTERNAL GEAR

• Internal gears are used for transmitting power between two parallel shafts. In these gears, annular
wheels are having teeth on the inner periphery. This makes the drive very compact .
• In these drives, the meshing pinion and annular gear are running in the same direction.
• Their precision rating is fair. They are useful for high load and high speed application with high
reduction ratio.
• Applications of these gears can be seen in planetary gear drives of automobile automatic
transmissions-, reduction gearboxes of cement mills, step-up drives of wind mills.
• Watch this planetary gear vedio

https://www.youtube.com/watch?v=ARd-Om2VyiE

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 1.8 RACK AND PINION

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BEVEL GEAR
• Bevel gears are used for transmitting power between intersecting shafts. They can operate under
high speeds and high loads. 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.
• Bevel gears are classified in different types according to geometry:
• Straight bevel gears have conical pitch surface and teeth are straight and tapering towards apex.
• Spiral bevel gears have curved teeth at an angle allowing tooth contact to be gradual and
smooth.
• Zerol bevel gears are very similar to a bevel gear, but the teeth are curved: the ends of each tooth
are coplanar with the axis, but the middle of each tooth is swept circumferentially around the
gear. Zerol bevel gears can be thought of as spiral bevel gears, which also have curved teeth, but
with a spiral angle of zero, so the ends of the teeth align with the axis.
• Hypoid bevel gears are similar to spiral bevel, but the pitch surfaces are hyperbolic and not
conical. The pinion can be offset above or below the gear center, thus allowing larger pinion
diameter, longer life, and smoother mesh. If the beveled surface is made parallel with the axis of
rotation, this configuration resembles a worm drive. Hypoid gears were widely used in
automobile rear axles.
• https://en.wikipedia.org/wiki/Bevel_gear
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SPIREL BEVEL GEAR
Spiral bevel gears shown in 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.

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 HYPOID BEVEL GEAR

• These gears are also used for right angle drive in which the axes do not intersect. This permits the
lowering of the pinion axis which is an added advantage in automobile in avoiding hump inside the
automobile drive line power transmission.
• However, the non – intersection introduces a considerable amount of sliding and the drive requires
good lubrication to reduce the friction and wear. Their efficiency is lower than other two types of
bevel gears.
• 24/04/2024
These gears are widely used in current day automobile drive line power transmission. 23
1.9 WORM GEAR

• Worm and worm gear pair consists of a worm, which is very similar to a screw and a worm gear,
which is a helical gear as shown in Fig. 1.25. They are used in right-angle skew shafts.
• In these gears, the engagement occurs without any shock. The sliding action prevalent in the
system while resulting in quieter operation produces considerable frictional heat.
• High reduction ratios 8 to 400 are possible. Efficiency of these gears is low anywhere from 90% to
40%.
• Higher speed ratio gears are non-reversible. Their precision rating is fair to good. They need good
lubrication for heat dissipation and for improving the efficiency. The drives are very compact.

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• Worm gearing finds wide application in material handling and transportation machinery, machine
tools, automobiles etc. An industrial worm gear box used for converting horizontal to vertical
drive is shown in Fig. 1.26.

1.10 Spiral gear

• Spiral gears are also known as crossed helical gears, Fig. 1.27. They have high helix angle and
transmit power between two non-intersecting non-parallel shafts. They have initially point contact
under the conditions of considerable sliding velocities finally gears will have line contact. Hence,
they are used for light load and low speed application such as instruments, sewing machine etc.
Their precision rating is poor. An application of spiral gear used in textile machinery is shown in
Fig. 1.28.

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24/04/2024 26
 TABLE 1 SUMMARY AND EVALUATION OF GEAR TYPES

Type Features and precision rating Applications Comments regarding

precision
Parallel shafting Applicable to all types of trains Simplest tooth elements
High speeds and loads highest and a wide range of velocity offering maximum precision.
efficiency ratios. First choice, recommended
Precision Rating is excellent for all the gear meshes, except
Spur where very high speeds and
loads or special features of
other types, such as right
angle drive, cannot be avoided

Parallel Shafting. Most applicable to high speeds Equivalent quality to spurs,

Very high speeds and loads. and loads; also used whenever except for complication of
Efficiency slightly less than spur spurs are used. helix angle.
Helica mesh. Recommended for all high-
l Precision Rating is good speed and high-load meshes.
Axial thrust component must
be accommodated.
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 Type Features and precision rating Applications Comments regarding
precision
Crossed Skewed shafting Relatively low velocity To be avoided for precision
Helical Point contact ratio; low speeds and light meshes. Point contact limits
High sliding loads only. capacity and precision. Suitable
Low speeds Any angle skew shafts for right angle drives, if light
Light loads load.
Precision Rating is poor A less expensive substitute for
bevel gears. Good lubrication
essential because of point of
contact and high sliding action.

Internal Parallel shafts Internal drives requiring
Spur High speeds high speeds and high loads;
High loads offers low sliding and high
Precision Rating is fair stress loading; good for high
capacity, long life.
Used in planetary gears to
produce large reduction
ratios
Not recommended for precision
meshes because of design,
fabrication, and inspection
limitations.
Should only be used when
internal feature is necessary.

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Type Features and precision Applications Comments regarding precision
rating
Intersecting shafts Suitable for 1:1 and Good choice for right angle drive, particularly
High speeds higher velocity ratios low ratios.
High loads and for right-angle However complicated both form and
Precision Rating is fair to meshes (and other fabrication limits achievement of precision.
Bevel good angles) Should be located at one of the less critical
meshes of the train.

Right-angle skew shafts, High velocity ratio Worm can be made to high precision, but
High velocity ratio, Angular meshes worm gear has inherent limitations.
High speeds and loads, Low High loads To be considered for average precision
Worm efficiency, Most designs meshes, but can be of high precision with
mesh nonreversible. care.
Precision rating is fair to Best choice for combination high velocity
good ratio and right-angle drive.
High sliding requires excellent lubrication

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(Continued) TABLE 1 SUMMARY AND EVALUATION OF GEAR TYPES

Features and Comments Regarding Precision

Type Applications
Precision Rating

Specials - Intersecting and skew shafts. Special cases To be avoided as precision meshes.
Face, Spiroid, Modest speeds and loads. Significant non-conjugate action with
Helicon, Precision Rating is fair to good departure from nominal center
Beveloid distance and shaft angles. Fabrication
needs special equipment and
inspection is limited.

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1.11 Law of Gearing
•

Pinion Gear
Number of teeth:Z Z1 Z2
Diameter(mm):d d1 d2
Speed(rpm):N N1 n2
Speed(rad/s):W w1 w2

In order to maintain constant angular velocity ratio between two meshing

gears, the common normal of the tooth profiles, at all contact points with in
mesh, must always pass through a fixed point on the line of centers, called
pitch point.
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 1.12 PROFILES SATISFYING LAW OF GEARS
• Profiles which can satisfy the law of gearing are
shown in Fig.
• These are
• (a) involute
• (b) cycloidal and
• (c) circular arc or Novikov.
• Among these, cycloidal was the first to be
evolved.
• This is followed by the invention of involute
profile which replaced many of the other
profiles due to several technological advantages.
• Circular arc or Novikov profile has some
advantages over the other profiles.
• But due to manufacturing difficulties, it did not
become popular. However with powder
metallurgy process it is slowly getting into
industry now for specific application.
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