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The geometrical proportions of a gear will depend on several factors. Normally, the following
parameters are given from which the designer has to proceed in his task.
1.
2.
3.
4.
5.
6.
7.
Accuracy of gears
The accuracy of the output of a gear depends on the accuracy of its design and manufacturing.
The correct manufacturing of a gear requires a number of prerequisite calculations and design
considerations. The design considerations taken into account before manufacturing of gears are:
Strength of the gear in order to avoid failure at starting torques or under dynamic loading
during running conditions.
We will now take up the individual data of gear parameters for proper design.
Material
Besides strength considerations, the choice of material mainly depends on the requirements of
space and weight and the overall price of the gear drive.
Cast iron is good enough for ordinary purposes.
Steel and cast steel offer better strength.
Pinion of synthetic material is quiet running and vibration damping.
Phosphor bronze and similar materials are used to alleviate the loss due to sliding.
The gear material should have the following properties:
Good manufacturability
Generally cast iron, steel, brass and bronze are preferred for manufacturing metallic gears with
cut teeth.
Where smooth action is not important, cast iron gears with cut teeth may be employed.
Commercially cut gears have a pitch line velocity of about 5 metre/second.
For velocities larger than this, gear sets with non-metallic pinions as one member are used to
eliminate vibration and noise. Non-metallic materials are made of various materials such as
treated cotton pressed and moulded at high-pressure, synthetic resins of the phenol type and
rawhide. Moisture affects rawhide pinions. Gears made of phenolic resins are self-supporting on
the other hand other two types are supported by metal side plates at both ends of the plate.
Large wheels are made with fretting rings to save alloy steels. Wheel centre is commonly cast
from cast iron. The ring is forged or roll expanded from steel of the respective grade specified by
the tooth design.
Number of Teeth
The number of teeth of the pinion and the gear are to be so chosen that a minimum value of
contact ratio 1.1 is assured.
For fast moving set, it should be greater than 1.5.
The transmission ratio should not preferably be a whole number to ensure hunting tooth action.
Guidelines for the selection of minimum number of teeth of pinion are given in Table 1.
When the number of teeth is below the minimum specified in Sec. 2.10, then obviously the pinion
is to be positively corrected.
To avoid interference:
14o full depth
20o full-depth
zmin = 32
zmin = 17
20o stub
zmin = 14
o
25 full-depth
zmin = 12
For the sum (or difference) of number of teeth of pinion and gear, the following rule holds good
For external gearing z1 + z2 >=24, and for internal gearing z2 z1 >=10
In a gear drive, two types of curves, the cycloidal and the involute, are generally used. In a gear
drive, the shape of the tooth depends upon the pressure angle. Gears of involute profile with
14.5, 20 full-depth and 20 stub pressure angles are most commonly used in industries. A 20
pressure angle full-depth involute gear tooth has various advantages over the other pressure
angles. BIS has recommended the use of 20 pressure angle full depth involute gear tooth
Transmission Ratio
If the transmission ratio is high, a multi-stage gear set is used to avoid unnecessarily big gears.
In general, the transmission ratio per stage is given by
i = 17 for general purpose drive
= 10 for maximum value in special cases
= 4 for maximum value for change-gear sets
If the given transmission ratio cannot be strictly adhered to for some technical ground, the
following deviations are allowed:
For all types of drives excluding worm-drive when i <= 250, the allowable deviation = +-3%
For all types of drives including worm-drive when i > 250, the allowable deviation = +-5%
A two-stage, step-up gearbox drives a compressor and has a lubrication pump mounted on one of
the gear shafts, Fig. 1. Tables 1, 2, and 3 show the spur-gear data, tolerances for tooth errors, and
polar moments of inertia for the masses in the compressor drive. All gears in the drive have 20
pressure angles. The gears are made of steel; the compressor is made of cast iron. A 50-hp (37.3kW) motor drives the gearbox at 3550 rpm. What are the dynamic loads on this gearbox?
CONSTRUCTING
TRANSMISSIONS
MATHEMATICAL
MODELS
FOR
ANALYZING
HYDROSTATIC
Substituting,
Substituting,
Substituting,
Figure 1: Shaft and 6-spoked bearing system having three rotor masses. ( Product Engineering.)
SI values
P
(44,480 N)
Is
= 25 in 4
(1040.6 cm 4)
IR
= 0.3 in 4
(12.5 cm 4)
(45.2 cm 2)
Es
= E R = 10 x 10" psi
(68,900 MPa)
= 10 in
(25.4 cm)
= 12 in
(30.5 cm)
CR
= 0.40 in
(8.9 cm)
(1.02 cm)
Symbols
SI values
(cm 2)
(crn)
SI values
P
(44,480 N)
(cm)
(kPa)
R RI = axial loading in inclined spokes, lb; (+ for upper two, ? for lower two)
(N)
(N)
F T =...