Unit 4 - Spur Gear - ABP PDF

SPUR GEAR REV 00
Prof. Amit B. Belvekar-Patil Machine Design

SPUR GEAR: SYLLABUS REV 00
John Deere 3350 tractor cut in Technikmuseum Speyer Museum

MECHANICAL DRIVES REV 00
What is Mechanical Drives?
Need of mechanical drives ?
A) To reduce speed (Ex. Overhead crane)
B) To get variable speed (Ex. Lathe machine)
Types of mechanical drives
1. Transmitting power by means of friction.
e.g. Belt drives and Rope drives
2. Transmitting power by means of engagement.
e.g. Chain drives and Gear drives
Selection of Mechanical Drive.

INTRODUCTION REV 00
Let the wheel A be keyed to the rotating shaft and the wheel B to the shaft, to be rotated.
A little consideration will show, that when the wheel A is rotated by a rotating shaft, it will rotate the wheel B in
the opposite direction as shown in Fig. (a).
The wheel B will be rotated (by the wheel A) so long as the tangential force exerted by the wheel A does not exceed
the maximum frictional resistance between the two wheels.
But when the tangential force (P) exceeds the frictional resistance (F), slipping will take place between the two
wheels. Thus the friction drive is not a positive drive.
In order to avoid the slipping, a number of projections (called teeth) as shown in Fig. (b), are provided on the
periphery of the wheel A, which will fit into the corresponding recesses on the periphery of the wheel B.
 A friction wheel with the teeth cut on it is known as toothed wheel or gear.

GEARS REV 00
1.Gears are toothed wheels which can transmit power & motion from one shaft to another shaft
by means of successive engagement of teeth.
2.Gear drive is provided when distance between two shaft is small
3.Gear drive is positive drive. i.e. No slipping.
4.Gear drive consists of two wheels small one called pinion while larger one is called gear.

Gear Drive – Significance REV 00
1. Positive drive
2. Compact construction
3. Large power transmission
4. Power transmission at very low speed
5. Very high efficiency
6. Wide range of velocity ratio

CLASSIFICATION OF GEARS REV 00
GEARS
NONINTERSECTING NONINTERSECTING
PARALLEL AXES INTERSECTING
AXES GEARS & PERPENDICULAR & NONPARALLEL
GEARS AXES AXES
Spur Gear Bevel Gear  worm and worm gears  Spiral Gears
Helical Gear
 Herringbone Gear
Rack and Pinion

Parallel shaft Axes Gears

1. Spur Gear
2. Herringbone Gears
3. Helical Gear
4. Rack and Pinion

SPUR GEAR REV 00
Teeth are parallel to axis of rotation

Transmit power from one shaft to another parallel shaft
Used in Electric screwdriver, windup alarm clock, washing machine
and clothes dryer
Advantages-
1. Easy to manufacture
2. Less expensive
3. Efficiency is up to 98%
Disadvantages-
1. Not used for high speed applications due to noisy operation.

SPUR GEAR: EXTERNAL & INTERNAL REV 00
EXTERNAL SPUR GEAR INTERNAL SPUR GEAR

RACK & PINION REV 00
Rack and pinion gears are used to convert rotary motion (From the pinion) into linear motion (of the rack)
 Rack Has no curvature having infinite radius
 Lathe Machine, Drilling Machine
RACK

HELICAL GEAR REV 00
The teeth on helical gears are cut at an angle to the face of the gear (Helix)
Two mating gears have same helix angle but opposite hands
This gradual engagement makes helical gears operate much more smoothly and quietly than spur gears.
Used at high velocity & load capacity applications
Subjected to both radial & tangential load ALONG WITH AXIAL LOAD
Machine tool gearbox,
Automobile gear box
Advantages-
1. Operation is smooth and quietly
2. Efficiency is up to 99%
3. Suitable for high speed applications
Disadvantages-
1. Difficult to manufacture.
2. Exerts end thrust

HERRINGBONE GEAR REV 00
To avoid axial thrust, two helical gears of opposite hand can be mounted side by side, to cancel resulting
thrust forces
Double helical gear
Herringbone gears are mostly used on heavy machinery.

BEVEL GEAR REV 00
Bevel gears are used for transmitting motion between two intersecting shafts at desired angle.
Surface of bevel gear is like frustum of cone.
The teeth on bevel gears can be straight, spiral
locomotives, marine applications, automobiles, printing presses, cooling towers, power plants, steel
plants, railway track inspection machines, etc.

WORM GEAR REV 00
Worm gears are used when large gear reductions are needed. It is common for worm gears to have reductions of 20:1, and
even up to 300:1 or greater.
Self locking or Non reversible.
Many worm gears have an interesting property that no other gear set has: the worm can easily turn the gear, but the gear
cannot turn the worm.
Worm gears are used widely in material handling ,machine tools, automobiles steering Mechanisms, Lifts, Cranes

Selection of Type of Gear REV 00
Type of Shaft layout Speed Input Speed and Cost

gear reduction Power to be
transmitted
Spur Parallel 6:1(10:1) Low and medium Cheapest

speed
Helical Parallel 6:1(10:1) High speed power Costlier

transmission
Bevel Perpendicular 1:1(3:1) Low speed Costlier
Worm Perpendicular 60:1(100:1) Low speed Costlier

and non-intersecting

SPUR GEAR: NOMENCLATURE REV 00

Pitch circle: It is an imaginary circle which by pure rolling

action would give the same motion as the actual gear.
Pitch circle diameter: It is the diameter of the pitch circle. The
size of the gear is usually specified by the pitch circle diameter. It
is also known as pitch diameter.
Pitch point: It is a common point of contact between two pitch
circles.
Pressure angle or angle of obliquity: It is the angle between the
common normal to two gear teeth at the point of contact and the
common tangent at the pitch point.
It is usually denoted by φ.
The standard pressure angles are 14 1/2 ° and 20°.

Addendum: It is the radial distance of a tooth from the pitch

circle to the top of the tooth.
Dedendum: It is the radial distance of a tooth from the pitch

circle to the bottom of the tooth.
Addendum circle: It is the circle drawn through the top of the

teeth and is concentric with the pitch circle.
Dedendum circle: It is the circle drawn through the bottom of

the teeth. It is also called root circle.
Circular pitch: It is the distance measured on the circumference

of the pitch circle from a point of one tooth to the corresponding
point on the next tooth. It is usually denoted by Pc
Pc= π m

Diametral pitch: It is the ratio of number of teeth to the pitch circle diameter
in millimeters. It is denoted by pd. Mathematically,
Module: It is the ratio of the pitch circle diameter in millimeters to the number of teeth.
It is usually denoted by m.
Mathematically,
Clearance: It is the radial distance from the top of the tooth to the bottom of the tooth,
in a meshing gear. A circle passing through the top of the meshing gear is known as
clearance circle.
Total depth: It is the radial distance between the addendum and the dedendum circles
of a gear. It is equal to the sum of the addendum and dedendum.
Face of tooth: It is the surface of the gear tooth above the pitch surface.
Flank of tooth: It is the surface of the gear tooth below the pitch surface.
Top land: It is the surface of the top of the tooth.
Face width: It is the width of the gear tooth measured parallel to its axis.

MESHING OF GEARS REV 00

Gear ratio : G=Zg/Zp=mZg/mZp=dg/dp
Center Distance: (a)=(dp+dg)/2

GEAR TOOTH FAILURE REV 00
Gear tooth
failure
BENDING WEAR
FAILURE FAILURE
PITTING SCORING ABRASIVE WEAR CORROSION WEAR
DESTRUCTIVE
INITIAL PITTING
PITTING

BENDING FAILURE OF GEARS REV 00

PITTING FAILURE OF GEARS REV 00

SCORING OF GEARS REV 00
Lubrication failure.. Inadequate lubrication

Abrasive Wear REV 00
Particles trapped between the matting surfaces.

Dirt entering in the gear box.
Use of oil filters
Increase surface hardness

Corrosive Wear REV 00
Chemical Action by improper lubricants

FORCES ON SPUR GEARS REV 00

Concept Module…..???
Module specifies the

size of the gear
AMIT BELVEKAR MECH ENGG MIT AOE


Law of Gearing REV 00
Common normal to the tooth profile at the

point of contact should always pass
through a fixed point called the pitch pitch
to obtain constant velocity ration

Interference & Undercutting

Backlash
Difference between width of tooth space and tooth
thickness.
It prevents mating teeth from jamming together.
Compensate thermal expansion.

Compensates machining error

Standard Systems Of Gear Tooth
Interference occurs when

Number of teeth on pinion is
less than 23.
Interference occurs when

Number of teeth on pinion is less
than 17.
Reduce interference
Reduce undercutting
Tooth is broader at root.
Standard Systems Of Gear Tooth
Shorter addendum
Interference occurs when Number
of teeth on pinion is less than 14.
Vibrations occurs.

Standard Proportions of Gear Tooth

Beam Strength of a Spur Gear Tooth REV 00
LEWIS EQUATION FOR BEAM STRENGTH

 Beam Strength :
Maximum tangential load the gear tooth can take
without tooth breakage (bending failure).
 Assumptions:
1. Full load acting at tip of single tooth.
2. Radial force effect neglected.
3. Load uniformly distributed across the full face width.
4. Frictional forces due to teeth sliding are neglected.
5. Effect of stress concentration neglected.

LEWIS EQUATION FOR BEAM STRENGTH REV 00

REV 00

LEWIS FORM FACTOR REV 00
 Function of tooth shape (but not size) and the point of

application of load.
Y 1.No of teeth 2.Tooth system 3.Pt application of load
2.87
Y  0.484  ( 20 full depth)
Z
2.64
Y  0.55  ( 20 stub)
Z
2.15
Y  0.39  (14.5 full depth)
Z

Wear Strength of a Spur Gear Tooth REV 00
 Wear Strength :
Maximum tangential load the gear tooth can take without pitting
failure.
Fw= dp*b*Q*k
Q=Ratio factor for external gear pair
=2 Zg /(Zg+Zp)
K= load stress factor N/mm2

 Effective Load on Gear Tooth REV 00
 Actual Load on gear tooth to transmit power Static & Dynamic Load on tooth
 Tangential Load + Dynamic Load
Effective Load Feff
Tangential Load Dynamic Load

Ftmax Fd
Feff  Ft max  Fd

 Maximum Tangential Load F tmax : REV 00
Compressor
 Maximum Tangential Load (Ftmax ) is given by
Ft max  k a K m Ft
Where Ka is Service / Application / Overload factor
Motor
Ka Depends upon application
Driving and Driven elements
Max Torque
Ka 
Rated Torque

Ka is Service / Application / Overload factor REV 00

Load Distribution Factor/ Load concentration Factor Km REV 00
Load distribution factor non distribution of load across the face of the tooth

Dynamic Load on Gear Tooth Fd REV 00
 Ka and Km does not account for inertia forces arising due to tooth errors.
 Gear tooth are not perfect due to inaccuracy in tooth profile, error in tooth spacing run out of gear and deflection
of tooth under load results in transmission error.
 Transmission error causes cyclic fluctuation of speed ratio.
 So during meshing each tooth undergoes short period of acceleration and deceleration
 This acceleration and deceleration combined with mass of pinion and gear results in inertia forces.
 So this additional force arises due to inertia forces are dynamic force
 Dynamic load depends on
 1. Tooth error
 2. Pitch Line velocity

Calculation Dynamic load (Fd) REV 00
Preliminary Estimation Precise Estimation
 Preliminary Estimation:
3 m
KV  V  10
3 V s
6 m 3 .6 m
KV  V  20 KV  20  V  25
6 V s 3 .6  V s
5 .6 m
KV  25  V  30
5 .6  V s
REV 00
 Kv factor accounts dynamic load
Ft max Ka Ft Km
Feff  
kV KV
 Precise Estimation
 Buckingham Approach

Dynamic Load on Gear Tooth Fd REV 00

REV 00
 According to Buckingham Approach Fd is given by
21V bC  Ft max  K is constant, depends on

Fd 
21V  bC  Ft max  tooth form
K=0.107 -14.50
 E p Eg
ke 
C   ke   K=0.111 - 200 Full depth
 1   E p  Eg 
1
    
K=0.115 - 200 stub
E E 
 p g 

Deformation Factor REV 00

Tolerances REV 00

REV 00
Problem 1 : A spur pinion having 21 teeth to be made of plain carbon steel 55C8 ( Sut=720 N/mm2) is
to mesh with a gear to be made of plain carbon steel 40C8 ( Sut=580 N/mm2).The gear pair is required to
transmit 22 KW power from an IC engine running at 1000 rpm to a machine running at 300 rpm. The
starting torque required is 200% of rated torque while the load distribution factor is 1.5. The factor of
safety required is 1.5. The face width is ten times module and tooth system is 20 full depth involute. The
gears are to be machined to meet the specifications of grade 6. The gear and pinion are to be case
hardened to 400 BHN and 450 BHN resp. The deformation factor C for gear pair is 11500e N/mm. Design
the gear pair by using dynamic factor Kv= 6/6+v and the buckingham’s equation for dynamic load.

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SPUR GEAR REV 00

Prof. Amit B. Belvekar-Patil Machine Design

John Deere 3350 tractor cut in Technikmuseum Speyer Museum

Prof. Amit B. Belvekar-Patil Machine Design

What is Mechanical Drives?

Need of mechanical drives ?

A) To reduce speed (Ex. Overhead crane)

B) To get variable speed (Ex. Lathe machine)

Types of mechanical drives

1. Transmitting power by means of friction.

e.g. Belt drives and Rope drives

2. Transmitting power by means of engagement.

e.g. Chain drives and Gear drives

Selection of Mechanical Drive.

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

3. Large power transmission

4. Power transmission at very low speed

5. Very high efficiency

6. Wide range of velocity ratio

Prof. Amit B. Belvekar-Patil Machine Design

Rack and Pinion

Prof. Amit B. Belvekar-Patil Machine Design

Parallel shaft Axes Gears

Prof. Amit B. Belvekar-Patil Machine Design

Teeth are parallel to axis of rotation

Prof. Amit B. Belvekar-Patil Machine Design

EXTERNAL SPUR GEAR INTERNAL SPUR GEAR

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Type of Shaft layout Speed Input Speed and Cost

Spur Parallel 6:1(10:1) Low and medium Cheapest

Helical Parallel 6:1(10:1) High speed power Costlier

Bevel Perpendicular 1:1(3:1) Low speed Costlier

Worm Perpendicular 60:1(100:1) Low speed Costlier

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Pitch circle: It is an imaginary circle which by pure rolling

Prof. Amit B. Belvekar-Patil Machine Design

Addendum: It is the radial distance of a tooth from the pitch

Dedendum: It is the radial distance of a tooth from the pitch

Addendum circle: It is the circle drawn through the top of the

Dedendum circle: It is the circle drawn through the bottom of

Circular pitch: It is the distance measured on the circumference

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Gear ratio : G=Zg/Zp=mZg/mZp=dg/dp

Center Distance: (a)=(dp+dg)/2

Prof. Amit B. Belvekar-Patil Machine Design

PITTING SCORING ABRASIVE WEAR CORROSION WEAR

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Prof. Amit B. Belvekar-Patil Machine Design

Lubrication failure.. Inadequate lubrication

Prof. Amit B. Belvekar-Patil Machine Design

Particles trapped between the matting surfaces.