MECHANICAL ENGINEERING DEPARTMENT LOGO

Machine Design & CAD - II

GEAR DESIGN PROJECT

Rack & Pinion Gear Design

GROUP MEMBERS

Khalil Raza Bhatti 07ME40 GL

07ME34 AGL
Ayaz Ali Soomro 07ME31
07ME36

Waqas Ali Tunio

Waqar Ahmed Bhutto

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Contents
1

Introduction

Design Methodology

Design Consideration

Design Calculation

Conclusion

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Project Objectives:
Understand
rack
and
pinion
gear
mechanism.
Come up with an innovative solution for
building that design as a standard one.
Determine the various forces that are
meshed within gears.
In context of all the gear parameters referring
to right selection of material for rack and as
well as for pinion.

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Need
Need is to develop a system for closing and
opening of railway crossing gate with rack
and pinion mechanism.
In order to design that we will have to
assume some data as shown:
Gate is to slide on a rail by rail and wheel mechanism.
Sliding path is frictionless.
Two rack and pinion gears are used to slide gate on rail as load
will uniformly be distributed mounted on its ends.

Rack and Pinion Gear Design

Rack & Pinion Gear

A rack and pinion gears system is
composed of two gears. The normal round
gear is the pinion gear and the straight or
flat gear is the rack.
The rack has teeth cut into it and they mesh
with the teeth of the pinion gear.
.

Pinion

Rack

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Basic Mechanism

Rack and Pinion Gear Design

Rack & Pinion Gear

contd.

Rack and pinion gears provide a greater

feedback and steering sensation.
A well designed mechanism such as the rack
and pinion gears save effort and time.
.

Rack and Pinion Gear Design

Rack & Pinion Gear

contd.

Rack and Pinion Gear Design

Designing Rack & Pinion Gear.

Engineering Design
.

Identify a Need
Conceptual Design
Preliminary Design
Designing Rack & Pinion Gear

Final Design
Manufacture
Sales & Delivery

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Rack & Pinion

Rack & Pinion
Two types
Rack and pinion gears are available in two variations

Straight teeth
or
Spur Type

Helical teeth
or
Helical Type

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Design Requirements
Basic Design Characteristic

Speed

Force

Effort

Rack & Pinion

Max:
Weight
Dimensions

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Preliminary Design
For spur gear design, pinion and rack both
have straight teeth or spur geometry of teeth.
So for we will first consider the design of
pinion as spur gear.

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Spur Gear Design and Selection

Objectives

Calculate forces on teeth of spur gears, including

impact forces associated with velocity and
clearances.
Determine allowable force on gear teeth, including
the factors necessary due to angle of involute of
tooth shape and materials selected for gears.
Understand how lubrication can cushion the impact
on gearing systems and cool them.

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Specifications for standard Gear Teeth

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Forces on Spur Gear Teeth

Ft = Transmitted force
Fn = Normal force.
Fr = Resultant force
= pressure angle
Fn = Ft tan
Fr = Ft/Cos

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Forces on Spur Gear Teeth

Power, P; =

Torque,

Combining the above we can write:

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Surface Speed
Surface speed (Vm) is often referred to as
pitch-line speed:

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Strength of Gear Teeth

Lewis form factor method
Lewis equation

Fs = Allowable dynamic bending force (lb)

Sn = Allowable stress. Use endurance limit and account for the

fillet as the stress concentration factor
b = Face width (in.)
Y = Lewis form factor (From Table)
Pd = Diametral pitch

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Lewis form factors (Y)

Table

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Classes of Gears
Transmitted load depends on the accuracy
of the gears
Gear Manufacture
Casting
Machining
Forming
Hobbing
Shaping and Planing
Forming

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Force Transmitted
Transmitted load depends on the accuracy of
the gears.
A dynamic load factor is added to take care
of this.
Ft = Transmitted force
Fd = Dynamic force
Commercial

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Classes of Gears
Carefully cut

Precision

Hobbed or shaved

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Expected error in tooth profiles

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Design Methods
Strength of gear tooth should be greater
than the dynamic force; Fs Fd
You should also include the factor of safety,
Nsf.

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Service Factors

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Face width of Gears

Relation between the width of gears and the
diametral pitch.

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Dynamic Beam Strength of the Gear

To increase the dynamic beam strength of
the gear
Increase tooth size by decreasing the diametral pitch
Increase face width upto the pitch diameter of the
pinion
Select material of greater endurance limit
Machine tooth profiles more precisely
Use proper lubricant and reduce contamination

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Buckingham Method of Gear Design

It offers greater flexibility.
Expected error is based on different-pitch
teeth.
More conservative design.

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Wear strength (Buckingham)

Fw = tooth wear strength.

Dp = diametral pitch of pinion.
Dg = diametral pitch of gear.
b = face width.
Kg = load stress factor.

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Reference
www.gearmanufacture.com
www.rackandpinion.design.net
www.gearfactory.com
www.mechanicaldesign.com
Wikipedia search
Machine Design R.S. Khurmi
Hand book of mechanical engineering.

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Conclusion
So far we have been able to calculate the
design of pinion only in the next phase of
project we will be designing the rack.
Passed on fundamental knowledge of rack
and pinion gear mechanism and it design
procedure & finally selecting the right
material for it.

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