Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Module 2 - GEARS
Lecture 4: WORKED OUT PROBLEMS ON INVOLUTE SPUR GEARS
Content
4.1 Introduction
4.2 Gear Calculation -Worked example 1
4.3 Gear Calculation -Worked example 2

4.1 INTRODUCTION
In the earlier lectures, the definition of gear, gear terminology, interference, methods of
eliminating interference, standard tooth systems for spur gears, profile shifted gears,
involutometry and design of gear blanks were dealt in detail. With the background of the
above knowledge, solving of simple gear problems will be dealt in this lecture.

4.2 GEAR CALCULATION Worked out example 1

In a drive, a velocity ratio of 2.5 with a centre distance of 70 mm is desired. (a) Determine
the pitch diameter of the gears with 20o full depth involute teeth; (b) Is there any
interference in the system? If so, how will you avoid it? (c) Determine the contact ratio, (d)
Find the dedendum, addendum, root diameters and the tip clearance, (e) If the centre
distance is increased by 1.5%, what will be the new pressure angle?

i = 2.5;

C = 70 mm; = 20o;

Given Data:

It is an involute full depth tooth system ;

To be found:

m = ?;

Z1 = ? ;

d1 = ?;

Interference exists or not ?;

Z2 = ?;

d2 = ?;

CR = ?

We know that,
C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1) = 70 mm
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Indian Institute of Technology Madras

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

From the above,

i.e., m x Z1 = 40

Possible solutions for standard modules as can be seen from the table:

Solution I:

m = 2mm, Z1 = 20, Z2 = i. Z1 = 2.5 x 20 = 50

d1 = m Z1 = 2 x 20 = 40 mm

d2 =i d1 = 2.5 x 40 = 100 mm

STANDARD MODULES IN mm:

0.3

0.4

0.5

0.6

0.7

0.8

1.0

1.25 1.5

1.75

2.0

2.25

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

10

11

12

13

14

15

16

18

20

22

24

26

28

30

33

36

39

42

45

50 Further increase is in terms of 5 mm

Minimum number of teeth that can engage with the gear of 50 teeth without
interference is given by,

z12 + 2 z1 z2 =

4k(z2 + k)
sin 2

For full depth gears, k = 1. Substituting the values Z2 = 50, = 20o in the above
equation,
z12 2 z1 x50

4 x 1( 50 1 )
sin 2 20 o

z 2 + 100 z 1744 0
1
1

i.e., Z1min = 15 is the minimum permissible number of teeth without interference.

Since from the above it is seen that, Z1 > Z1min no interference will occur.

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Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Fig 4.1. Path of Contact

Contact ratio, CR:

Referring to fig. 4.1, the path of contact:

La = ua + ur

L ( r a )2 r 2 cos 2
a
1
1

( r a )2 r 2 cos 2 ( r r ) sin
2
2
1 2

Substituting the values,

L ( 20 2 ) 2 20 2 cos 2 20o ( 50 2 ) 2 50 2 cos 2 20o ( 20 50 ) sin 20o
a
9.798 mm

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Indian Institute of Technology Madras

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Now CR can be calculated with the formulae below,

CR

L
L
9.798
9.798
a
a

1.660
p cos m cos x 2 x cos 20o
5.901

For full depth tooth, the various values calculated are as shown below:
Addendum:

a = 1m = 1x2

= 2mm

Dedendum:

b = 1.25m = 1.25x2 = 2.5 mm

Clearance:

c = 0.25 m = 0.25x2

Pinion root circle diameter:

dr1 = d1- 2b = 40 2x2.5 = 35 mm

Pinion addendum diameter:

da1 = d1+ 2a = 40 + 2x2 = 44 mm

Gear root circle diameter:

dr2 = d2- 2b = 100 2x2.5 = 95 mm

Gear addendum diameter:

da2 = d2+ 2a = 100 + 2x2 = 104 mm

= 0.5 mm

Solution II:

The centre distance is given by, C = (r1 +r2) = 0.5 m ( Z1 + Z2) = 0.5 m (Z1 + i Z1)
= 70 mm

Simplifying, m x Z1 = 40

Another possible solution for standard module from the table is,
m = 2.5 mm, Z1 = 16, Z2 = i x Z1 = 40,
d1 = m Z1 = 2.5x16=40 mm,
d2 = m Z2 = 2.5 x 40 =100 mm

Minimum number of teeth that can engage the gear of 40 teeth without interference
is given by,

z12 + 2 z1 z2 =

4 k (z2 + k)
sin 2
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Indian Institute of Technology Madras

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

For full depth gears k = 1. Substituting Z2 = 40, = 20o, in the above equation,

4(40 + 1 )
z 2 + 2 z x 40 =
1
1
sin2 20o
z 2 + 80 z 1402 0
1
1

i.e., Z1min = 15 is the minimum permissible without interference.

Since Z1 > Z1min, no interference will occur.

Contact ratio, CR :
Referring to the fig. 4.1, the path of contact is given by,
La = ua + ur
L ( r a )2 r 2 cos 2
a
1
1

( r a )2 r 2 cos 2 ( r r ) sin
2
2
1 2

Substituting the values,

L ( 20 2.5 )2 20 2 cos 2 20 o
a
11.854 mm

( 50 2.5 )2 50 2 cos 2 20 o ( 20 50 ) sin 20 o

Now CR can be calculated as,

CR

L
L
11.854
11.854
a
a

1.607
p cos m cos
5.901
x 2.5 x cos 20o

For full depth tooth the values are,

Addendum :

a =1m = 1x2.5 =2.5mm

Dedendum :

b =1.25m =1.25x2.5 = 3.125 mm

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Indian Institute of Technology Madras

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Clearance:

c = 0.25 m = 0.25x2.5 = 0.625 mm

[Pinion root circle diameter:

dr1= d1- 2b = 40 2x3.125 = 33.75 mm

Pinion addendum diameter:

da1= d1+ 2a = 40+2x2.5 = 45 mm

Gear root circle diameter:

dr2= d2- 2b = 100 2x3.125 = 93.75 mm

Pinion addendum diameter:

da2= d2+ 2a = 100 + 2x2.5 = 105 mm

New Pressure angle when the centre distance C is increased by 1.5% is given by:
= cos-1( r1 cos20o / r1 1.015) = 22.21o

4.3 GEAR CALCULATIONS- Worked out example 2

A 21 teeth gear has 20o full depth involute teeth with a module of 12mm. (a) Calculate the
radii of pitch circle, base circle and addendum circle (b) Determine the tooth thickness at
base circle, pitch circle and addendum circle. Comment on the top land thickness.

rb
cos

inv tan

t
t 2 r ( 1 inv inv )
2r
1
Fig 4.2 Involutometry
The terminologies used in the problem are explained in earlier chapters. Hence the figures
referred are self explanatory.
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Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

Fig. 4.3 Layout for tooth thickness determination at any point on tooth profile

Given Data: Pressure angle, =20o = 0.349 rad., Z1 = 21, m= 12mm.

Solution:
r1 = 0.5.m.Z1 = 0.5 x 12 x 21=126 mm
rb = r1.Cos = 126 x cos 20o = 118.4 mm
a = 1m = 1 x 12 = 12 mm
ra = r1 + a = 126 + 12 = 138 mm
p1 = .m = . 12 = 37.14 mm
t1 = 0.5 p1 = 0.5 x 37.14 = 18.57 mm
inv = tan - = tan 0.349 0.349 = 0.015 rad
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Indian Institute of Technology Madras

Machine Design II

Prof. K.Gopinath & Prof. M.M.Mayuram

At the base circle b= 0, Hence tooth thickness tb at the base circle is:
t
t 2 r ( 1 inv inv )
b
b 2r
b
1
18.57
2 x 118.4 x(
0.015 0 ) 21.0 mm
2 x126

At the addendum circle the pressure angle is given by,

a=cos-1(rb/ra) =cos-1(118.4 /138) =0.54 rad
inv a = tan 0.54 0.54 = 0.059

Hence tooth thickness ta can be calculated as,

t
t 2 r 1 inv inv
a
a 2r
a
1

Substituting the values,

18.57

t 2 x 138 x
0.015 0.059 8. 20 mm
a
2 x 126

Minimum recommended top land thickness is,

tamin = 0.25 m = 0.25 x 12 = 3 mm

From the above, we know that, ta > tamin, hence the tip thickness is adequate and
permissible.

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