ESFA 2003 R 10

THE GEAR SYNTHESIS WITH THE BEST EFFICIENCY

Relly PETRESCU1, Florian PETRESCU2
Chair GDGI, Bucharest Polytechnic University, ROMANIA, victoriap@emoka.ro
2
Chair TMR, Bucharest Polytechnic University, ROMANIA,

ABSTRACT
The paper presents an original method to determinate the efficiency of the gear. The originality
of this method consist in the eliminated of the friction modulus. On analyze the influence of few
parameters about the efficiency value. These parameters are: z1 - the number of tooths for
the primary wheel of gear; z2 - the number of tooths for the secondary wheel of gear; 0 the pressure angle normal on the divided circle; - the inclination angle. With the relations of
this presentment, on can synthesizing the gear mechanisms.
KEY WORDS: efficiency, gear, constructive parameters, tooth, wheel, circle.

INTRODUCTION
In this paper the authors presents an original method to calculate the efficiency
of the gear.
The originality
n
2002 Victoria PETRESCU
2
consist in the way
to determinate the
t
efficiency of the
v2
gear, because on
F
are not utilized the
1
friction forces of
P
F
m
couple (this new
way eliminate the
v1
rp1
classical method).
1
F
K1
On eliminate too
the necessity to
v12
determinate
the
rb1
t
friction coefficients
O1
by
different
n
1
experimental
0
1
methods.
The
determinates
Fig. 1. The forces of the gear
efficiency by the
new method is the same like the classical efficiency, namely the mechanical
efficiency of the gear.
The model taken in calculation is very simple. It can be fallowed in figure 1.

63

1. THE DETERMINATE OF THE MOMENTARY MECHANICAL EFFICIENCY

The calculating relations are the next (see the fig. 1):
F = Fm . cos1

(1)

F = Fm . sin1

(2)

v2 = v1 . cos1

(3)

v12 = v1 . sin1

(4)

where:
_
_
_
Fm = F + F
_
_
_
v1 = v2 + v12
with:

wheel);
wheel);

(5)
(6)

Fm
F
F
v1

- the motive force (the driving force);

- the transmitted force (the useful force);
- the slide force (the lost force);
- the speed of element 1, or the speed of wheel 1 (the driving

v2

- the speed of element 2, or the speed of wheel 2 (the droves

v12 - the relative speed of the wheel 1 in relation with the wheel 2
(this is a sliding speed).
The consumed power (in this case the driving power) will be writhed with the
relation (7):
Pc = Pm = Fm . v1

(7)

The useful power (the transmitted power from the profile 1 to the profile 2) will
be writhed:
Pu = P = F . v2 = Fm .cos1 .v1 .cos1

(8)

Pu = Fm .v1 .cos2 1

(8)

The lost power will be writhed:

P =F .v12 =Fm .sin1 .v1 .sin1

(9)

P = Fm . v1 .sin2 1

(9)

The momentary efficiency of couple will be determinate directly with the next
relation:

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(10)

i = Pu / Pc =P /Pm =Fm.v1.cos21 / Fm.v1

i = cos2 1

(10)

The momentary losing coefficient will be writhed:

(11)

i =P /Pm = Fm.v1.sin21 / Fm.v1 = sin21

On can see easily that the sum of the momentary efficiency and the momentary
losing coefficient will be always 1:
i +i = cos21 +sin21 =1

(12)

And now on shall determinate the geometrical elements of gear. These

elements will be utilized to the determination of the efficiency of the couple, .
2. THE GEOMETRICAL ELEMENTS OF GEAR
On shall be determinate the next geometrical elements of gear:
The radius of the basic circle of wheel 1 (of the driving wheel):
rb1 = 1/2.m.z1 .cos0

(13)

The radius of the head circle of wheel 1:

ra1 = 1/2.(m.z1 +2.m)=m/2.(z1 +2)

(14)

On determinate now the maximum of pressure angle of the gear:

cos1M =rb1 /ra1 =1/2.m.z1 .cos0 /[1/2.m.(z1 +2)]=z1 .cos0 /(z1 +2)

(15)

And now on determinate the same parameters for the wheel 2, the radius of
basic circle and the radius of the head circle for the wheel 2:
rb2 = 1/2.m.z2 .cos0

(16)

ra2 = 1/2.(m.z2 +2.m)=m/2.(z2 +2)

(17)

Now on can determinate the minimum of pressure angle of the gear:

tg1m =[(rb1 +rb2 ).tg0 -sqrt(r2a2 -r2b2 )]/rb1=N/rb1
N=1/2.m.(z1 +z2 ).sin0 -sqrt[(m/2)2 .(z2 +2)2 -(m/2)2 .z22 .cos20 ]
(19)

65

(18)

N=m/2.[(z1 +z2 ).sin0 -sqrt(z22 .sin2 0 +4.z2 +4)]

(20)

With the relation (20) the relation (18) become the relation (21):
(21)

tg1m =[(z1 +z2 ).sin0 sqrt(z22.sin20 +4.z2 +4)]/(z1 .cos0)

Now on can determinate the minimum (22) and the maximum (23) for the
pressure angle:
1m =atan{[(z1 +z2 ).sin0 -sqrt(z22.sin20 +4.z2 +4)]/(z1 .cos0 )}
(22)
1M = acos[z1 .cos0 /(z1 +2)]

(23)

3. DETERMINATING THE EFFICIENCY

The efficiency of gear will be determinate through the integration of momentary
efficiency on all section of gearing movement, namely from the minimum pressure
angle to the maximum pressure angle:
M
= 1 / . i . d
m
M
= 1 / . [cos2 .d]
m
M
= 1/(2.). [2.cos2.d]
m
M
= 1 / (2.). { [cos(2.)+1].d}
m
M
= 1/(2.). [1/2.sin(2.)+]
m

(24)

(25)

(26)

(27)

(28)

=1/(2.).{1/2.[sin(2.M)-sin(2.m)]+}

(29)

= [sin(2.M) - sin(2.m)] / [4 . (M - m)] + 0.5

(30)

Finally the efficiency of gear will be calculated with the relation (30), utilizing for
the pressure angle the relation (22) for the minimum and the relation (23) for the
maximum, in case of utilizing the gear with right teeth (=0) and in case of utilizing
the gear with bended teeth (0) on shall be use for the determination of the extreme
pressure angles the relations (32) and (33).

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t =atan(tg0 /cos)

(31)

m=atan{[(z1+z2)/cos.sint -sqrt(z22/cos2.sin2t+4.z2 /cos+4)].cos/(z1.cost )}

(32)
M = acos[z1 /cos.cost /(z1 /cos+2)]

(33)

Continuing to see some calculated relations on shall see how the efficiency is
varying with the input parameters.

Table 1 The calculated efficiency for the right

teeth

4. THE CALCULATED
EFFICIENCY

i12effective= - 4

right teeth

z1 =8
0 =200 ?
m = -16.220 ?
M=41.25740

z2 =32
0 =290
m = 0.71590
M=45.59740
=0.8111

Table 1
0 =350
m = 11.13030
M=49.05600
=0.7308

We shall see now four table with

the calculated efficiency in function of
the input parameters and once the
proceed from results we shall take some z1 =10
z2 =40
0
conclusions.
0 =20 ?
0 =260
0 =300
0
0
The input parameters are:
m = -9.89 ?
m = 1.3077
m = 8.22170
z1 = the number of tooths for the M=38.45680
M=41.49660
M=43.80600
driving wheel 1;
=0.8375
=0.7882
z2 = the number of tooths for the
droves wheel 2, or the ratio of z1 =18
z2 =72
0
transmission, i (i12=-z2/z1);
0 =19
0 =200
0 =300
0
0
0 = the pressure angle normal on m = 0.9860
m =2.7358
m =18.28300
the divided circle;
M=31.68300
M=32.25050
M=38.79220
= the bend angle.
=0.90105
=0.8918
=0.7660
We begin with the right teeth (the
toothed gear), with i=-4, once for z1 we z1 =30
z2 =120
shall take successively diverse values, 0 =150
0 =200
0 =300
in growth (in rise), starting from 8 m = 1.50660
m =9.53670
m =23.12250
tooths.
M=25.10180
M=28.24140
M=35.71810
On can see that for 8 tooths of the =0.9345
=0.8882
=0.7566
driving wheel the standard pressure
angle, 0=200, is to little for to can it be z1 =90
z2 =360
utilized (on obtain a minimum pressure =80 ?
0 =90
0 =200
0
angle, m, negative and this fact is not =-0.16380 ? =1.58380
m =16.49990
m
m
admitted!).
M=14.36370
M=14.93540
M=23.18120
In the second table we shall
=0.9750
=0.8839
diminish (in module) the value for the
ratio of transmission, i, from 4 to 2.
On shall see how for the littler values to the number of tooths to the wheel 1,

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Table 2

Table 3 The calculated efficiency

The calculated efficiency

i12effective= - 6

right teeth

z1 =8
0 =200 ?
m=-17.860 ?
M=41.25740

z2 =48
0 =300
m = 1.77840
M=46.14620
=0.8026

0 =350
m =10.6600
M=49.05590
=0.7337

z1 =10
0 =200 ?
m=-11.120 ?
M=38.45680

z2 =60
0 =260
m =0.60540
M=41.49660
=0.8403

0 =300
m = 7.73910
M=43.80600
=0.7908

0 =300
m =18.69350
M=38.79220
=0.7633

z1 =18
0 =190
m =0.42940
M=31.68300
=0.9028

z2 =108
0 =200
m =2.24490
M=32.25050
=0.8935

0 =300
m =18.12800
M=38.79220
=0.7670

z2 =60
0 =200
m =10.04160
M=28.24140
=0.8859

0 =300
m =23.27740
M=35.71810
=0.7555

z1 =30
0 =150
m =1.09220
M=25.10180
=0.9356

z2 =180
0 =200
m =9.34140
M=28.24140
=0.8891

0 =300
m =23.06660
M=35.71810
=0.7570

z2 =180
0 =200
m =16.56670
M=23.18120
=0.8836

0 =300
m =27.78250
M=32.09170
=0.7507

z1 =90
0 =90
m =1.36450
M=14.93540
=0.9754

z2 =540
0 =200
m =16.47630
M=23.18120
=0.8841

0 =300
m =27.75830
M=32.09170
=0.7509

i12effective= - 2

right teeth

Table 2

z1 =8
0 =200 ?
m=-12.650 ?
M=41.25740

z2 =16
0 =280
m = 0.91490
M=45.06060
=0.8141

z1 =10
0 =200 ?
m = -7.130 ?
M=38.45680

z2 =20
0 =250
m = 1.33300
M=40.95220
=0.8411

0 =30
m = 9.41060
M=43.80600
=0.7817

z1 =18
0 =180
m = 0.67560
M=31.13510
=0.9052

z2 =36
0 =200
m =3.92330
M=32.25050
=0.8874

z1 =30
0 =140
m =0.88450
M=24.54270
=0.9388
z1 =90
0 =80
m =0.52270
M=14.36370
=0.9785

0 =350
m =12.29330
M=49.05590
=0.7236

Table 3

the standard pressure angle (0=200) is to little and on shall be necessary to increase
it
to a minimum value. For example, if z1=8, the necessary minimum value is 0=290 for
an i=-4 (see the table 1) and 0=280 for an i=-2 (see the table 2). If z1=10, the
necessary minimum pressure angle is 0=260 for i=-4 (see the table 1) and 0=250 for
i=-2 (see the table 2).
When the number of the tooths to the wheel 1 increase, we can decrease the
normal pressure angle, 0. On can see that for z1=90 we shall take a very little value
for the normal pressure angle (for the pressure angle of reference), 0=80.
In the table 3 on increase the module value for i (for ratio of transmission), from
2 to 6.
Table 4

The calculated efficiency for the bended teeth

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The table 4 keep

for i the initial value (i=4), but now we shall
operate with bended
teeth (0). For this
table
(for
this
calculation) we shall
take for a normal
value,
=150.
The
bending of the teeth are
not so much influence
to the value of the gear
efficiency.
For
this
reason we do not
changed
again
the
bending of the teeth ().

i12effective= - 4

bend teeth
=15

z1 =8

Table 4

z2 =32
0 =300

0 =350

m=-16.8360 ?

m = 1.12650

m = 9.44550

M=41.08340

M=46.25920

M=49.29530

=0.8046

=0.7390

0 =20

z1 =10

z2 =40
0 =260

0 =300

m=-10.5630 ?

m =0.23550

m = 6.91880

M=38.34740

M=41.571390

M=43.99650

=0.8412

=0.7937

0 =20

CONCLUSIONS
z1 =18

z2 =72

After the analyzing 0 =190

0 =200
0 =300
of the four table on can
0
m =2.02830
m =17.18400
take
the
next m =0.32715
M=31.71800
M=32.32020
M=39.18030
conclusions:
- the efficiency =0.9029
=0.8938
=0.7702
(of the gear)
increase when
z2 =120
the number of z1 =30
0
0 =200
0 =300
tooths for the 0 =15
driving wheel m =1.02690
m =8.86020
m =22.15500
1, z1, increase =25.13440
M=28.45910
M=36.25180
M
too and that
=0.8899
=0.7593
when
the =0.9357
pressure
angle,
0, z1 =90
z2 =360
diminish;
0
0 =9
0 =200
0 =300
- z2 or i12 are not
0
m =15.89440
m =26.94030
so
much m =1.3187
influence about M=14.96480
M=23.63660
M=32.82620
on
the =0.9754
=0.8845
=0.7513
efficiency
value;
- on can see
easily that for the value 0=200, the efficiency take roughly the value 0.89
for any values of the others parameters (this justify the choice of this value
0=200 for the standard pressure angle of reference). But the pressure angle
of reference, 0, can be decreased in the same time with the increase of the
number of tooths for the driving wheel 1, z1, in reason to increasing the gear
efficiency, ; contrary, when we desire to realize an gear with a little z1 (for a

69

little gauge), it will be necessary to increasing the 0 value, for maintaining a

positive value for m (in this case the gear efficiency will be diminished);
the module of the gear, m, have not any influence about on the gear
efficiency value; when 0 is diminished on can take a bigger normal module,
for increasing the addendum of tooth, but the increase of the m in the same
time with the increase of the z1 can lead to a greater gauge;
when increase, the efficiency, , increase too but the growth is
insignificant;
the gear efficiency, , is really a function of 0 and z1: =f(0, z1);
m and M are just the intermediate parameters.

BONUS: THE RELATIONS TO CALCULATING THE EFFICIENCY FOR THE

INTERNAL GEAR
On calculate the values for the extreme angles, m and M with the relations (35), (36)
respective (39), (38) and then on utilize the same relation (30) like in the external
gear case.
A. THE DRIVING WHEEL 1, HAVE EXTERNAL TEETH
tgt=tg0/cos

(34)

tg1m=[(z1 - z2)/cos.sint + (z22/cos2.sin2t - 4.z2/cos + 4)1/2]/[z1/cos.cost]

cos1M=z1/cos.cost/(z1/cos + 2)

(35)
(36)

B. THE DRIVING WHEEL 1, HAVE INTERNAL TEETH

tgt=tg0/cos

(37)

tg1M=[(z1 - z2)/cos.sint + (z22/cos2.sin2t + 4.z2/cos + 4)1/2]/[z1/cos.cost]

cos1m=z1/cos.cost/(z1/cos - 2)

(38)
(39)

REFERENCES
[1] Petrescu, V., Petrescu, I., Antonescu, O. Randamentul cuplei superioare de la
angrenajele cu roi dinate cu axe fixe. PRASIC 02, Braov, Romania, 2002, Vol. I,
p. 333-338.
[2] Petrescu, I., Petrescu, V., Ocnrescu, C. The cam synthesis with maximal
efficiency. PRASIC 02, Braov, Romania, 2002, Vol. I, p. 339-344.
[3] Antonescu, P., Petrescu, R., Adr, G., Antonescu, O. Mecanisme cu roi dinate.
Editura Printech, Bucureti, 1999.
[4] Pelecudi, Ch., .a. Mecanisme. EDP, Bucureti, 1985.

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