GRS

AN INTRODUCTION TO GEARS
An Introduction to Gears
Connecting Devices
Fasteners.
Hoses & Couplings.
Seals & Gaskets.
Bearings.
Gears.
Why are Gears Used?
Gears are used in machine to

transmit motion and energy.
can change speed,
torque
and direction
in an efficient manner.
How are the Gears Fastened to the Shafts?

Gear teeth MESH or engage.
The DRIVE GEAR causes a gear
in mesh with it to be DRIVEN.
Power is usually transferred to and

from gears by shaft, and gears
must be firmly fastened to shafts.

Splines
Machining of grooves on the

shaft and in the gear hub.
Gear pushed onto the shaft

the splines mate, and the
gear cannot slip on the shaft.
Sometimes the splines are not
a tight fit; the gear can slide
sideways on the long splines.

Keys
A long Square (Bar) Key :

a single slot in the hub and
a groove in the shaft.
Woodruff Key : semi-circular in

shape and fits into a curved
recess in the shaft. The gear is
then slid over it.

Integral Part
Sometimes small gears are an

integral part of the shaft
(gear
pump, small drive trains).
Dont try to remove them!
one piece
Principles
Two gears
Shafts will rotate in
OPPOSITE directions.
Third gear - IDLER - will change

the direction of rotation.
Drive and driven gear turn in
SAME direction.
Gear Teeth Mesh
Two gears - GEAR SET

Smaller gear - PINION
Three or more - GEAR TRAIN
What Type of Mechanical Advantage is Obtained?
Most gears transmit motion

on parallel shafts.
- or to change the direction of

motion.
Gears can make power flow

from one place to another.
But other changes can occur if
the gears are different sizes.
We call this :
MECHANICAL ADVANTAGE.

More Torque
Less Speed
Speed
Advantage
or a Torque
Advantage
More Speed
Less Torque
Gears can never give us power advantage.

The change is mechanical advantage.
Gear Ratio
48 TEETH
Proportional to the radii of the gears.

24 TEETH
By counting gear teeth.
Pinion 1/3 the large gear size.

Gear Ratio
1:2
2:1
The first number in the ratio is

usually the gear to which power is
applied.
Power flow from
the pinion (24 teeth)
to
the
large gear (48 teeth),
the ratio is 24 to 48
- or 1:2.
If the power flow is reversed
the ratio will be 2:1.
Gear Ratio
A single idler gear does not

change the gear ratio. It can
have any number of teeth.
When torque increased, shaft

size may also be increased.
Torque is a twisting force.
Teeth
SPUR TEETH straight across
Teeth
Gear Tooth Profile
Involute Curve
Gear Measurement
Pressure Angle = 14
Providing rolling contact

rather than sliding contact.
Provides a strong tooth &

allows smooth, full-depth tooth
engagement.
Teeth
All gears in a gear train must

have teeth that are compatible
in size and shape.
FACE WIDTH the width

of a gear across the teeth.
Gear Tooth Clearance

BACKLASH
If gears bind:
If gears too loose:
Slight clearance:
Excessive friction
Noisy
Allow lubrication
Power loss
Inefficient
Max. efficiency
Gear teeth damage
Gear teeth damage
Timing Gears & Timing Marks
4 Crankshaft
3 Camshaft
2 & 5 Idlers gears
1 Accessory drive gears
6 Oil pump drive gear
Marked tooth fits into a similarly

marked groove on the mating gear.
Two timing marks

Timed with the reference to a

fixed point.
Timed
Not Timed
Use of Gears
Tractor Final Drive
Bull gear- increases torque

reduces speed
Second set of final drive

Double Reduction.
Use of Gears
Motor Grader Final Drive
Tandem rear wheels

driven by sprockets
and chains.
Drive sprockets on a shaft driven by the final drive gear.

Bevel Gears
Used between the transmission and final drives to
transfer engine power at right angles so wheels or track
can be driven.
Bevel Gears
Straight Bevel Gears

Faces and axes
intersect at a 90 angle
Spiral Bevel Gears

Considerable overlap
carry greater loads
Open in the center and bolted to a

flange BEVEL RING gear
Bevel Gears
Bevel gears tend to separate, and
transmit force back along their shafts.
THRUST LOADS
Tapered Roller Bearing

Large roller ends toward the gear
Bevel Gears
Endplay
Measuring Endplay
Differentials
When turning, the outside wheels turn
faster than the inside they cover a
greater distance.
Pinion drives a bevel gear,

The bevel gear has
an attached housing.
SPIDER GEARS two or

more small, free turning bevel
gears inside the housing.
Helical Gears
Teeth cut on an angle Helix

longer tooth - quieter operation
Right - Hand
Left - Hand
Helical Gears
Transmit motion on
Parallel shafts.
Cross helical at angles up to 90

Light loads - extreme tooth angle.
Worm Gears
The DRIVE WORM
is a screw that
makes sliding contact
with a driven WORM
GEAR
Helical worm face is

curved inward to provide
better tooth contact
Worm Gears
50
50: 1
- offer large speed reduction a

single-threaded worm turns
the worm gear ONE tooth for
each revolution of the worm
- Gear has 50 teeth
gear ratio = 50: 1
- The worm would have to turn
50 times to make the gear to
turn once.
Tapered roller bearings are used.

Rack and Pinion
Straight
Semi-Circular
The shaft drives a worm and worm

gear, turning a pinion that engages
a RACK
Drive Train Gears
Thank You
!
Gears are an integral part of all drive train components,

i.e. transmissions, final drives, differentials,
torque dividers, etc
Drive train gears work together to reduce engine speed and
increase torque as it passes through the system.
3 main types of gears used in Caterpillar drive train systems
1) Spur gears 2) Bevel gears 3) Helical gears.
Transmission gears must :
provide long life and durability in a high-speed environment
(e.g. load and carry applications).
Final drive gears must :
- withstand high torque loads at lower speeds for extended
periods of time.
- must also be able to withstand extreme shock
loads
generated by torque spikes
Drive Train Gears

Function
-Reduce engine
speed and
increase torque
Types
-Spurs gears
-Bevel gears
-Helical gears
Drive Train Gears

Transmission gears
- Long-term durability in a high-speed operation

Final drive gears
- Withstand extreme shock loads

- Withstand continuous high loads over long periods of time
Drive Train Gears -- Characteristics
Design
Metallurgy
Manufacturing
Application Customization
Design
- Fillet geometry
- Tooth profile
- Crown geometry
- Surface finish

Design - Fillet Geometry
Competition
Caterpillar
Flat root
Round Root
Small stress relieving area
Large stress relieving area
Stress concentrations

Design - Tooth Profile
Competition
Caterpillar
No crown
Crowned
Stress on tooth ends
Distributes stress under
Leads to breakage
deflection
Protects teeth tips

Design - Crown
Competition
No crown
Stress on tooth ends
Leads to breakage
Caterpillar
Crowned
Distributes stress under
deflection
Protects teeth tips

Metallurgy
Material chemistry
Heat treat selection
Proprietary heat treat
methods

Metallurgy - Heat Treat
Competition
Inadequate hardness
Insufficient hardness depth
Reduced life
Caterpillar
Deep hardened teeth
Heat Treat Processes

Caterpillar uses several heat treatment processes
to best match the gear to its designed need.
Nitride Hardening
- on parts that require only a shallow case
depth or have very fine teeth.
Induction (Through) Hardening
- where high bending strength is required but
there is no need for high pitting resistance
because of the low number of cycles.
Case Carburized Hardening
- for highly loaded gears undergoing a high number
of cycles, (final drive, sun gears & pinions).
- high bending strength - resistance to pitting and
scoring. Carburizing creates finely distributed
carbides at the surface to meet these needs.

Manufacturing
Special tooling
Hobbing
Shaping
Grinding
CBN grinding
Quality control

Application Customization
Product knowledge
Tooth thickness customization
Tooth profile optimization
Latest engineering changes
Drive Train Gears - Field Test

D8K Final Drive
Cat on one side and "will fit" on the other
- "Will fit" failed at 2191 hours

- No failures on Cat side
- Had 1000's of hours left

D8K Final Drive
"Will fit" failure due to
- Lack of crown
- Improper heat treat

D8K Final Drive
"Will fit" failure due to
Dimensional inaccuracies
- Improper mesh
- Oversize OD
- No crown
Material
- Insufficient hardness
- Insufficient hardness depth
Drive Train Gears - Summary

Caterpillar Commitment
Research and development
Continuous improvements in,
Design, Materials, Metallurgy,

Manufacturing, Heat treatment,
Quality Control
Parts built to be reused
Published reusability guidelines
Lower life-cycle costs
Parts continuously updated to provide service life
improvements
Parts built to Cat specs for Cat machines
Superior parts availability
Drive Train Gears - Summary

Competitors Commitment
Try to copy Cat Dimensions and appearance
Lower parts reusability
Avoid the subject
No reusability guidelines
Increased life cycle costs
Outdated technology
Parts built with no knowledge of Cat system specs
or the machine operating requirements

Incomplete product line

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AN INTRODUCTION TO GEARS

Why are Gears Used?

Gears are used in machine to

How are the Gears Fastened to the Shafts?

Power is usually transferred to and

How are the Gears Fastened to the Shafts?

Machining of grooves on the

Gear pushed onto the shaft

How are the Gears Fastened to the Shafts?

A long Square (Bar) Key :

Woodruff Key : semi-circular in

How are the Gears Fastened to the Shafts?

Sometimes small gears are an

Third gear - IDLER - will change

Gear Teeth Mesh

Two gears - GEAR SET

Three or more - GEAR TRAIN

What Type of Mechanical Advantage is Obtained?

Most gears transmit motion

- or to change the direction of

What Type of Mechanical Advantage is Obtained?

Gears can make power flow

What Type of Mechanical Advantage is Obtained?

Gears can never give us power advantage.

Proportional to the radii of the gears.

By counting gear teeth.

Pinion 1/3 the large gear size.

The first number in the ratio is

A single idler gear does not

When torque increased, shaft

SPUR TEETH straight across

Providing rolling contact

Provides a strong tooth &

All gears in a gear train must

FACE WIDTH the width

Gear Tooth Clearance

If gears too loose:

Gear teeth damage

Gear teeth damage

Timing Gears & Timing Marks

Timing Gears & Timing Marks

Marked tooth fits into a similarly

Two timing marks

Timed with the reference to a

Timing Gears & Timing Marks

Tractor Final Drive

Bull gear- increases torque

Second set of final drive

Motor Grader Final Drive

Tandem rear wheels

Drive sprockets on a shaft driven by the final drive gear.

Straight Bevel Gears

Spiral Bevel Gears

Open in the center and bolted to a

Tapered Roller Bearing

Large roller ends toward the gear

Pinion drives a bevel gear,

SPIDER GEARS two or

Teeth cut on an angle Helix

Cross helical at angles up to 90

Helical worm face is

- offer large speed reduction a

Tapered roller bearings are used.

Rack and Pinion