MECH3030 Mechanisms of Machinery

Mechanisms: Introduction to Gear Trains

Jaguar 3.8 Litre, 6 cylinder

Norton Chap 9
1

Chapter 11: Introduction to Gear Trains

Spur gear: gear with radial teeth parallel to its axis
Rack and pinion: a mechanism in which a toothed wheel (pinion)
engages a notched bar (rack) to convert rotary motion into linear motion
Bevel Gear: Either of a pair of toothed wheels whose working surfaces are
inclined to nonparallel axes.
axes Example: differential in automobile
Helical gear: a gear that has the teeth cut at an angle to the
center line of the gear. It can operate quieter than spur gear
Worm and gear : A coarse, spiral shaped gear cut on a shaft. It is used to
engage with and drive another gear or portion of a gear.
Herringbone Gears (double helical gears): two helical gears operating together
and so placed that the angle of the teeth form a "V" shape; cancel out end-thrust
forces
2

Spur Gear
Axis of the gear

Spur gear: gear with radial teeth parallel to its axis

Backlash: the amount of "play" or clearance between two parts. For gears, it
refers to how much one gear can be moved back and forth without moving the
gear into which it is meshed

Rack & Pinion, Bevel Gear ()

Pinion

Rack
Either of a pair of toothed
A mechanism in which a toothed wheel (pinion) wheels whose working surfaces
engages a notched bar (rack) to convert
are inclined to nonparallel axes.
rotary motion into linear motion
Example: differential in
automobile
-Allow bi-directional drive
- rack-and-pinion steering in cars

Differential: a device that allows a difference in velocity (and displacement)

between two elements

Helical Gears

Helical gear: a gear that has the teeth cut at an angle to the
center line of the gear. This kind of gear is useful because there is
no chance of intermittent tooth-to-tooth operation because there are
at least two teeth engaged at any time. It can operate quieter than
spur gear. Helical gears are either right- or left-handed.

Worm Gear & Harmonic Gearing

Worm wheel
(worm gear)

Worm
A coarse, spiral shaped gear cut on a shaft. It is
used to engage with and drive another gear or
portion of a gear. As used in the steering gearbox,
it often engages the cross shaft via a roller or by a
tapered pin.

Ultra low backlash gear technology

with medium-high reduction ratios for
accurate bi-directional repeatability,
high efficiency and power to weight.

Very high gear ratio is possible in small package

6

Allow one directional drive: worm worm wheel

Good for motion control: robotics

Harmonic Gearing (Strain wave gear)

Wave Generator:
The wave generator is an oval-shaped cam. It is mounted onto the motor shaft
Flex Spline:
The flex spline is a thin, cup-shaped component made of elastic metal, with teeth
formed along the outer circumference of the cup's opening. The gear's output shaft is
attached to the bottom of the flex spline.
Circular Spline:
The circular spline is a rigid internal gear with teeth formed along its inner
circumference.
http://www.hds.co.jp/HDS_hp_english/english/products/index.html
http://www.harmonicdrive.net/reference/operatingprinciples/
7

http://www.youtube.com/watch?v=CSiHJPrycSA&feature=related

Herringhbone Gear & Gear Train

Herringbone Gears (double helical gears): two

helical gears operating together and so placed
that the angle of the teeth form a "V" shape;
cancel out end-thrust forces. no thrust
bearing is needed
8

http://content.scvs.tpc.edu.tw/top1/chap10/htm/chap10-12.htm

Differential Gear & Planetary Gear Train

http://www.youtube.com/watch?v=K4JhruinbWc
9

Differential Operation
When turning a corner:
The wheels must travel at different speeds to prevent tire scrubbing

10

Differential Operation

When turning a corner:

Differential pinion gears walk around slower side gear and cause
other side gear to turn faster
An equal percentage of speed is removed from one axle and given to
the other
The amount of torque applied to each wheel remains equal

11

Limited-Slip Differentials
Provide more driving force to
the wheel with traction when
one wheel begins to slip
Still allow the wheels
to rotate at different
speeds when turning
a corner
Are sometimes
called Posi-Traction,
Traction-Lok,
and Posi-Units
12

Video: http://bit.ly/1Hwu3qi

Limited-Slip Differential (LSD) - Torsen

Torsen differential
(torque sensing)
Designed by Vernon
Gleasman
GM
Audi
Lexus
Peugeot
Toyota
Volkswagen
13

Video: http://bit.ly/1HwueC4

Limited-Slip Differential (LSD) - Torsen

When the torque bias ratio (TBR)
is less than than 3:1 one wheel
can receive up to 75% torque
The other will get 25%

When the TBR is GREATER

than 3:1 the worm wheels
tighten on the worm gear and
the slower side receives torque
from the faster side

14

Tochigi Fuji Sangyuo ()

GKN Driveline: Limited-Slip Differential (LSD)
Torque Management Device (TMD)
- Active TMD
Electronic Torque Manager (ETM)
Electro magnetic Control Device
Electro-magnetic
Electronic Torque Vectoring
- Passive TMD
Visco Lok LSD, Viscous Coupling, Super LSD,
Helical LSD, Multi-plate LSD

15

Four-Wheel Drive (4WD)

16

4WD Purpose
Provide additional traction for off-road or poor
traction conditions
May provide a low range for increased torque
Some
S
units
it may have
h
provisions
i i
ffor PTO (P
(Power
Take-Off)

17

4WD VS. AWD

4WD
Generally is part-time
Generally provides a low range

AWD
Generally is full-time
Generally does not provide a low range
Generally contains a front to rear differential
http://www.youtube.com/watch?v=vuUaqFnsb2M
18

Components
Two drive axle assemblies
Front axle must be able to steer as well as drive
Gear ratios must match (front to rear)
Front drive axles have traditionallyy been solid ((nonindependent)
Independent front suspension is becoming much more
popular
Some AWD vehicles are built off of a FWD platform

19

Components
Transfer Case
An auxiliary transmission designed to split power between the
front and rear drive axles

Lock out hubs used to disengage the front wheels from

the drive axle
Increases highway fuel economy and reduces wear
May be automatic or manual
Automatic hubs react to input torque when transfer case is shifted into
4WD
May not unlock after shifting out of 4WD until vehicle is backed up (30-50ft)

20

Components

21

AM Generals Humvee, Hummer ()

1979: Armys High Mobility Multipurpose Wheeled Vehicle (HMMWV)

US$1.2billion for 55k Humvees, US$1.6billion for 70k Humvees
22

AM Generals Hummer (), Civilian

23

2011 Jeep Grand Cherokee - Drive Train

Quadra-Trac I
A light-weight single-speed case that automatically delivers full-time four-wheel drive.
Quadra-Trac II
Two-speed transfer case, with multiple sensors to detect tire slip, can direct up to 100 percent of available
torque to the axle with the most traction.
Quadra-Drive II
The industry leader in tractive capability, Quadra Drive II with Electronic Limited-slip Differential (ELSD) has a
4WD Low range mode that multiplies torque 2.72 times and locks clutch packs in the center differential for
24 performance in the most extreme conditions.

Kinematics of Gears

v A v O v A / O 0 1 rA / O
1k r1i 1 r1 j

v A v P v A / P 0 2 rA / P
2k ( r2 i ) 2 r2 j

1 r1 2 r2 or
Fundamental law of gearing:

2
r1

1
r2

Angular vel. Ratio = constant throughout the mesh torque ratio

25

How can the radii r1 and r2 be related to the number of

teeth on each gear?
Assume that the gears must have the same circular pitch
n1 = teeth on gear 1
n2 = teeth on gear 2

Pitch: the distance between a point on one gear tooth and the same
point on the next gear tooth
26

Simple gear set

O/P

I/P

Here, gears 3 & 4 are rigidly connected, as are gears 5 & 6

5
n4
3
n2
7
n6

4
n5
2
n3

n
Clearly 4 = 3 and 6 = 5

7 3 5 7
n 2 n 4 n6

2 2 4 6
n3 n5 n 7
27

The sign is necessary to take into account the change in direction of rotation.

Reverted gear train

Used in automotive transmission:

- compact, save space
Revert = go back to a previous state
28

Compare:

Internal gear

3 r2 n2

2 r3 n3

The + sign is used here to take into

account the direction of rotation.
29

Example: Find the speed reductions possible for the

transmission
22 = Gear teeth number
4 = Gear number
the power is transmitted
through gears 0456
1012.

If gear 34 slides to the left (disengaging 4 from 5) and gear 12 to the left
(engaging 1 and 9), then power is transmitted through 01961012
30

Example: Find the speed reductions possible for the

transmission
gear 12

gear 34
If gear 34 slides to the left
(disengaging 4 from 5) and
gear 12 to the left (engaging
1 and 9), then power is
transmitted through
g 0196
1012

Note: There are 8 possible speed

reductions.
31

Example: Find the gear reductions in the automotive transmission

Low gear: gear 3 meshes with
gear 6, power flows 1463.
Second gear: gear 2 meshes
with gear 5, power flows 14
52.
High gear: gear 2 is shifted so
that the clutch teeth on the
end of gear 2 mesh with the
clutch teeth of gear 1.
(Direct drive results.)
Reverse gear: gear 3 is shifted
to mesh with gear 8, power
flows 14783.
http://auto.howstuffworks.com/transmission3.htm
http://www.mattsauto.com/trans.html
http://www.youtube.com/watch?v=o-3SqMsgVdI
How Manual Transmission Works

32

Example: Find the gear reductions in the automotive transmission

power flows 1463

out

in low 1

out

in 2nd

33

n n
1 (1) 6
n4 n3
14 18

0.301
31 27

power flows 1452.

2
1

4 5 2

1 4 5

n n
1 (1) 5
n4 n2
14 25
0.564
31 20

4 6 3

1 4 6

out

in

1.000
Hi

Example: Find the gear reductions in the automotive transmission

power flows 14783.

out

3
in rev 1

4 7 8 3

1 4 7 8

n1 n7 n8
(1)
n4 n8 n3
14 14

0.234
31 27

34

Planetary gear train

Example: Find the output angular velocity 2 for the planetary gear train shown
when the input angular velocity is 4 = 50 rad/sec counterclockwise.
annulus

Sun (O/P)

Note that gear 2 and

arm 4 are not joined.
v A v C 3 rA/C

planet

4 k (r2 r3 )i 3k (r3i )

[(r2 r3 ) 4 r3 3 ]j
arm

v A 2 rA/O
1 annulus (80) (internal gear)

2 k r2 i

2 sun gear (40)

r2 2 j

3 planet gear (20)

4 arm
35

(1)
Program: 9-33.wm2d

r2 2 (r2 r3 ) 4 r3 3

(2)

v B v C v B/C
0 4 k rC / O 3k rB / C

n2 = 40
n3 = 20

4 k (r2 r3 )i 3k r3i
(r2 r3 ) 4 j r3 3 j

using the tooth relationship to replace the radii,

Substituting back into the other equation gives

36

Example: Find the gear ratios for the model T Ford gearbox
P2

P1

I/P

2: On

http://auto.howstuffworks.com/clutch.htm
Videoclip: http://bit.ly/18TVThj
http://bit.ly/18TVU4Q

O/P

Gearbox : Integral with the engine. Foot

operated 2 speed and reverse epicyclic
transmission foot-brake, 1908 for 19 y
yrs
S2

S1

9 million were made!

http://www.t-ford.co.uk/car.htm

Textbook p.507
37

Low gear for the model T Ford

Point B
in

out

Replacing the radii by the number of teeth

on the appropriate gears

http://auto.howstuffworks.com/transmission.htm

38

in

Point C

Example: Reversed Gear case

P2

P1

I/P

1:On

O/P

S2

S1

Textbook p.507
39

Reverse gear for the model T Ford

in

out

Note the negative sign indicating a change in direction

40

Reverse on a Car

http://www.innerauto.com/Automotive_Animations
41

Model T Ford, 1912 Landaulette

42

Towards the Involute Profile

A belt connecting the two cylinders

The involute is a curve traced by a point on a taut, inextensible

string as it unwinds from a circle.
http://www.ies.co.jp/math/java/calc/en-circum/en-circum.html

43

The Involute Profile

-The string is always tangent to the cylinder

-The center of curvature of the involute is always at the point of
tangency of the string with the cylinder
-A tangent to Involute is then always normal to String, the length
of which is the instantaneous radius of curvature of Involute curve

Involute curve: created by tying a pencil to the end of a string and wrapping the string
around a cylinder. Hold tension in the string as you unwind it from the cylinder. The
curve drawn by the pencil as it moves out from the cylinder is an involute curve.
44

Profile of the Involute Profile

Pressure angle = the angle between Line of Action (common normal) and the
direction of velocity at the pitch point (has been standardized: 14.5, 20, 25)

Line of action (common

normal)

Common
tangent

Line of action (common normal): A line normal to a pair of mating tooth profiles at their point of contact
45

Involute in Action

Pitch circle=rolling cylinder circle

Addendum: the amount of tooth that sticks out above the pitch circle
video from http://www.howstuffworks.com http://en.wikipedia.org/wiki/Involute_gear
Fundamental law of gearing: the common normal of the tooth profiles, at all contact
points within the mesh, must always pass through a fixed point on the line of centers,
called the pitch point
46

Nomenclature

Figure 11-8
47

pc

d
N

Pitches, Etc.

circular pitch (mm, in.)

b
base
pitch
it h (mm,
(
in.)
i )
diametral pitch (teeth/in.): US
module (mm/teeth): SI

48

pc

N
pb pc cos
N
pd
d
d
m
N

Minimum # of Teeth
minimum # of teeth to avoid undercutting with gear and rack

N min

2
2
sin

= pressure angle
49

Involute curve for involute gear

x a(cos sin )
y a(sin cos )
a = diameter of base circle
Commonly used in all kinds of power
transmission systems:
The center-to-ceter distance between two involute gears (common error in
manufacturing process) will not affect the velocity ratio!

http://mathworld.wolfram.com/CircleInvolute.html

50

Antons Calculus (7th): p.782

Origin of involute curve

T
t = angle

-sT
r
ri

x a (cos sin )
y a (sin cos )
51

Involute curve for tooth profile

52

Involute curve for tooth profile

arc DG BG
DOG

OG
OG
BG
tan B
OG
DOG tan B
DOB DOG B tan B B
DOA tan A A
0.5t B
t
(tan B B ) B
RB
2 RB
0.5t A
t
DOE DOA
(tan A A ) A
RA
2RA

DOE DOB

53

tA & tB = the tooth thickness at R = RA

RB respectively

tA

(tan A A ) (tan B B )
t B 2 RB
2
R
A

Involute curve for tooth profile

54

Length of Action Z for Gear (rg) and Pinion (rp)

Fig 9-6

Z (rp a p ) 2 (rp cos ) 2 (rg a g ) 2 (rg cos ) 2 C sin

55

Length of Action Z for Gear (rg) and Pinion (rp)

Fig 9-7

Z (rp a p ) 2 (rp cos ) 2 (rg a g ) 2 (rg cos ) 2 C sin

C = center distance,

Contact ratio mp = avg number of teeth in contact at any one time

= Z / pb

56

pb = base pitch = pc cos

mp, min=1.2

mp, spur = (1.4, 2)

Ceter distance errors will not change velocity

ratio of Involute Gear

57

58

Cycloid curve for cycloidal gear

Commonly used in watches and clocks

P(x,y)

x a a sin
y a a cos

http://mathworld.wolfram.com/Cycloid.html

59

The cycloid is the locus of a point on the rim of a

circle of radius rolling along a straight line

Antons Calculus (7th): p.93

Rack & Pinion

60

Bevel Gear

61

Worm Gear

62

Gear Train

63

Automotive Differential Gear

64

Manual Transmission
Low gear

65

Second gear

Gear Types Grouped According to Shaft Arrangement

Straight bevel: These are like spur gears, the teeth have no helix angle
Spiral bevel gears: Teeth have a spiral angle which gives performance improvements much
like helical gears
Zerol bevel gears: Teeth are crowned, so that tooth contact takes place first at the tooth
center. (Zerol Bevel Gears are Spiral Bevel Gears with a spiral angle of zero)
Hypoid gears: Similar to spiral bevel gears, but connect non-parallel shafts. The pitch
surface of this gear is a hyperboloid of revolution (rather than a cone, the pitch surface in
bevel gears). It is stronger, operate quietly, used for higher reduction ratios. Hypoid gears
are found in auto differentials.
66

Herringbone gears examples

from D.O. James Gear Manufacturing Co.

http://www.linngear.com/products/highlights/infosheets/g-3.html
67

Comparision between Helical Gear and Herringbone Gear

68

Bevel Gear: based on rolling cones

Apices must be
conincident

Incorrect arrangement

69

Correct arrangements

Spiral bevel Gear & Hypoid Gear

Spiral bevel Gears

Hypoid Gears are similar in their general

form to bevel gears. However, Hypoid
Gears operate on non-intersecting axes.
(Hypoid = a contradiction of hyperboloid)

70

Hypoid Gear: based on hyperboloids of revolution

Rolling hyperboloids of
revolution
71

Automotive hypoid final drive gears

(General Motors, Detroit, MI)

Hyperboloids: quadric surface generated by rotating a hyperbola around its

main axis (http://mathworld.wolfram.com/Hyperboloid.html)

Hypoid Gears
The centerline of the drive pinion gear intersects
the ring gear at a point lower than the centerline
They are commonly used in cars and light-duty
trucks
Their design allows for a lower vehicle height and
more passenger room inside the vehicle

72

Spiral Bevel Gears

The centerline of the drive pinion intersects
the centerline of the ring gear
They are usually used in heavy-duty truck applications
They are usually noisier than hypoid gears

73

Example: Automotive steering

74

Mechanism in Cars

75

Automatic Transmission in Cars (animation)

http://auto.howstuffworks.com/automatic-transmission6.htm
Videoclips: http://bit.ly/1BJTvk4, http://bit.ly/1BJU1OV, http://bit.ly/1BJU3X8
76

How Automatic Transmissions Work

http://auto.howstuffworks.com/automatic-transmission.htm
http://auto.howstuffworks.com/automatic-transmission18.htm

77

How Automatic Transmissions Work

78

How Automatic Transmissions Work

Planetary Gear Sets

Hydraulic System: transmission fluid via Oil Pump through the Valve
Body to control the Clutches and the Bands in order to control the planetary
gear sets.

S l and
Seals
d Gaskets
G k t are used to keep the oil where it is supposed to be
and prevent it from leaking out.

The Torque Converter which acts like a clutch to allow the vehicle to
come to a stop in gear while the engine is still running.

The Governor and the Modulator or Throttle Cable that monitor

speed and throttle position in order to determine when to shift.

79

How Automatic Transmissions Work

1. Provides automated control of vehicle launch

(starting the vehicle from a stop)
2. Selects the desired gear ratio
3 Shifts to the desired gear ratio
3.
4. Modifies the engine's speed/torque
5. Transmits power efficiently (helps provide good fuel
economy)

80

Helical Gears

81

Spur Gears with Full Depth 14 and Stub 20

82

How to make a gear: gear hobbing or CNC machining

Gear hobbing =
a multipoint machining process
gear teeth are progressively generated by a series of
cuts with a helical cutting tool (hob)
Both Hob & Workpiece revolve constantly as Hob is
fed across the face width of the gear blank

Gear generating process uses a helical hob cutter

Cutters and blanks rotate in a timed relationship
Maintains a proportional feed rate between the gear blank
and the hob
Cuts several teeth on a progressive basis
used for high production runs

Hob = a hard steel edge tool to cut gears

83

Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 19, Ngear = 37
Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
Gear ratio: mG = Ngear / Npinion = 37/19 = 1.947
1 947
Circular pitch pc = /pd = /6 = 0.524 in
Base ptich pb = pc cos = 0.524 cos(20)=0.492 in

84

Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37
Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
Pinions pitch diameter dp = Np /pd = 19/6 = 3
3.167
167 in
in, rp = dp /2 = 1
1.583
583 in
Gears pitch diamter

dg =Ng /pd = 37/6 = 6.167 in, rg = dg / 2 = 3.083 in

Nominal center distance C = sum of pitch radii

C = rp + rg = 4.667 in

85

Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37
Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearance, Ro, contact ratio of gearset with given parameters

Sol:
From Tabel 9-1 (p.
(p 471):
Addendum a = 1.0/pd = 0.167 in

Dedendum b = 1.25/pd = 0.208 in

Whole depth ht = sum of a & b = 0.167 + 0.208 = 0.375 in

Clearance = difference between dedendum and addendum

c = b-a = 0.208 0.167 = 0.042 in
86

Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37
Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Sol:
From Tabel 9-1 (p.
(p 471):
Outside diameter of each gear = pitch diameter plus 2 addenda
Dop= dp + 2a = 3.500 in

87

Dog= dg + 2a = 6.500 in

Example 9-1 Determine Gear Tooth & Gear Mesh Parameter

Given: pd = 6, pressure angle = 20, Npinion = 20, Ngear = 37
Find: Gear ratio, pc, pb, dp, Rp, center distance, addendum, dedendum, whole depth,
clearnace, Ro, contact ratio of gearset with given parameters

Z (rp a p ) 2 (rp cos ) 2 (rg a g ) 2 (rg cos ) 2 C sin

(1.583 0.1677) 2 (1.583 cos 20) 2 (3.083 0.167
7) 2 (3.083 cos 20) 2 4.667
7 ssin 20
0.798 in

Contact ratio

88

mp = Z/pb = 0.798/0.492 = 1.62

89

Ford Model Ts Gear Trains

90

Ford Model Ts Gear Trains

91

Ford Model Ts Gear Trains

92

Ford Model Ts Gear Trains

93