FMB 20202 Mechanics of Machine

Chapter IV Gear Trains

By
Engr. Syed Fawwaz Al-Attas

Content

Introduction

Types of Gear

Spur Gear

Gear Trains

Introduction

Power transmission is the movement of energy

from its place of generation to a location
where it is applied to performing useful work

A gear is a component within a transmission

device that transmits rotational force to
another gear or device

Introduction
What are Gears for?

Reducing or increasing speed and torque

Transmitting power from one point to another

Change direction of power

Split power

Performance demand (at various times)

Efficiency
Reliability
Accuracy
Smoothness
Quiet operation

Introduction
Torque vs Power vs Speed
Torque

Measurement of twisting force

Power
can

Measurement of how quickly work

be done

Speed
RPM

Gear rotational speed measured in

(Revolution per minute)

Introduction
Gears and shafts are basically wheel and axles,
but gears have cogs, or teeth on their
circumference

Introduction
External vs Internal Gear
An external gear is one with
the teeth formed on the
outer surface of a cylinder
or cone

An internal gear is one with

the teeth formed on the
inner surface of a cylinder
or cone

Introduction
Gears
turn
clockwise
or
clockwise.

either
counter-

The teeth of one gear

mesh (or engage) with the
teeth of another.
When gears touch, we call
it meshing.
As gears mesh, they turn
in opposite directions.

Introduction
Driver and Driven Gear
- Driver gear move first, as it connected to the energy
source
- The driven gear will move according to driver gear
- Two meshed gears always rotate in opposite directions

Driven gear

Driver gear

Introduction
Idler Gear
Idlers are used to reverse the direction of the gears

Driver

Idler gear

Driven

Types of Gear
According to the position of axes of the shafts

Parallel

Gears
Non-Parallel

- Spur Gears
- Helical Gears
- Herringbone Gears
- Rack and Pinion

- Bevel Gears
- Hypoid Gears
- Worm and Worm Gears

Types of Gear
Parallel Shafts
Spur Gears
Straight cut teeth
Teeth are parallel to the axis of the shaft
Transmit power from one shaft to another parallel
shaft
Advantages
Cost

Simplest gear design

Ease of manufacture

Availability
Disadvantages

Noisy operation

Only works with mating gear

Axis of each gear must be parallel

Used in Electric screwdriver, oscillating sprinkler,
windup
alarm clock, washing machine and clothes dryer

Types of Gear
Parallel Shafts

Helical
The Gears
teeth on helical gears are cut at an angle to the face of the gear

(Spiral cut teeth)

Teeth are at an angle to the gear axis (usually 10 to 45) called
helix angle
Advantages
Smooth and quiet due to gradual tooth engagements (at least two
teeth
are in mesh at any time), and also reduces impact
More tooth engagement allows for greater power transmission for
given
gear size
Disadvantage
More expensive
Resulting axial thrust component
Mating gear axis can be parallel or crossed
Can withstand the largest capacity at 30,000 hp

Types of Gear
Parallel Shafts
Herringbone
Gears
A herringbone
gear, also known as a double helical gear, is a special

type of
gear which is a side to side (not face to face) combination of two
helical gears
of opposite hands
From the top the helical grooves of this gear looks like letter V
Advantages
The double helical form balances the inherent thrust forces (T.F.=0)
Double helical gears give an efficient transfer of torque and smooth
motion at very high rotational velocities
Disadvantages
High cost due to special gear shaping equipment and cutting tools
Need special attention when assembling this gear with others
Mostly used on heavy machinery

Types of Gear
Parallel Shafts
Rack and Pinion
Gears
A rack and pinion
is a type of linear actuator that comprises a pair of
gears
which convert rotational motion into linear motion
The circular pinion engages teeth on a linear "gear" barthe rack.
Rotational
motion applied to the pinion will cause the rack to move to the side,
up to the
limit of its travel
This arrangement is commonly found in the steering mechanism of
cars or
other wheeled, steered vehicles, provides a lesser mechanical
advantage than
other mechanisms, but much less backlash and greater feedback

Types of Gear
Non-Parallel Shafts
Bevel
Gears
Used
when the direction of a shaft's rotation needs to be changed

Both of the shaft axis intersect and often mounted on 90 apart, but
can be
designed to work at other angles as well
The teeth can be Straight-toothed or Spiral
Advantages
This gear makes it possible to change the operating angle.
Differing of the number of teeth (effectively diameter) on each wheel
allows mechanical advantage to be changed
Disadvantages
Must be precisely mounted
The axes must be capable of supporting significant forces

Types of Gear
Non-Parallel Shafts
Hypoid
Gearsidentical
Is actually

with bevel gear, but its shaft axis does not

intersect
The teeth can be Straight-toothed or Spiral
Hypoid gears are stronger, higher torque, quieter and can be used for
higher
reduction ratios
However they also have some sliding action along the teeth, which
reduces
mechanical efficiency, the energy losses being in the form of heat
produced in
the gear surfaces and the lubricating fluid

Types of Gear
Non-Parallel Shafts
Worm and Worm
Gears
Its shaft axis
is perpendicular and non-intersecting

Consist of Worm Gear and Worm which resembles a screw, can

have right or left hand thread
The worm gear is always the drive gear
Able to reduce large rotational speed (~30:1) or allow higher torque
to be
transmitted
Worm
Advantages
Quiet / smooth drive
No back driving
Good for positioning systems
Disadvantages
Most inefficient due to excessive friction (sliding)
High wear gear mesh
Slower speed applications
Worm Gear

Spur Gear
(parallel axis)

Gear Nomenclature

Gear Nomenclature

Gear Nomenclature

h
itc

dia

ter
e
m

Gear Nomenclature

Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.)
that the
toothed gear may be considered to replace

Pitch circle: The circles remain tangent throughout entire engagement

Pitch Diameter: Diameter of pitch circle

Addendum circle: A circle bounding the ends of the teeth, in a right

section of the
gear

Dedendum circle: The circle bounding the spaces between the teeth, in a
right
section of the gear

Addendum: The radial distance between the pitch circle and the
addendum circle

Dedendum: The radial distance between the pitch circle and the root circle

Clearance: The difference between the dedendum of one gear and the
addendum of
the mating gear

Face of a tooth: That part of the tooth surface lying outside the pitch
surface

Flank of a tooth: The part of the tooth surface lying inside the pitch

Gear Nomenclature

D
N
n

v
T

= Pitch circle diameter (m)

= No. of gear teeth
= speed of gear (RPM)
= angular velocity (rad/s)
= pitch linear velocity (m/s)
= torque (N.m)

Subscript:
P = Driver gear
G = Driven gear

.D
PC circle:

Circular Pitch (Pc) : The width of a tooth and a space, measured on the pitch
N
.DP .DG
* ALL gears in mesh must have equalPP
:

C C
NP
NG
N
P

Diametral Pitch, (PD) : Number of teeth per meter of pitch diameter:

D
D
N P NG
P

* ALL gears in mesh must have equal P

D D:
DP DG

D
v .
2

The velocity v of any point on

the circle must be the same for
all the gears, otherwise they
would be slipping.

D
m
Module (m) : Pitch diameter divided by number of teeth:
N
DP DG

n
* ALL gears in mesh must have equalmm:
GearRatio P P G
N P NG
G nG N P

Gear Nomenclature
Example 1
A motor and a driven gear meshing with each other with the given
parameters below:
D

Gear P
(driver)

10 cm

15

Gear G
(driven)

20

n
350 RPM
b

0.8 rad/s

Determine:
(a) Circular Pitch,Pc , Diametral Pitch, Pd and Module, m
(b) Gear ratio
(c) a, b, c, d

Gear Nomenclature
Example 1
Solution:
(a) Circular Pitch,Pc = 0.021 m
Diametral Pitch, Pd = 150 m-1
Module, m = 6.7 x10-3 m
(b)

Gear ratio = 1.3 : 1

D

(c)

Gear P
(driver)

10 cm

15

350 RPM

Gear G
(driven)

0.133
m

20

262 RPM

1.07 rad/s
0.8 rad/s

0.053 m/s

Gear Nomenclature
The addendum, a is the radial
distance between addendum
circle and the pitch circle.
The dedendum, b is the radial
distance from the dedendum
circle to the pitch circle.

Pr essure angle ()
rp Pitch circle radius (m)

a 1 m

b 1.25 m

rb rP cos

D
2
rb Base circle radius (m)

rt rP a

rr Dedendum circle radius (m)

rr rP b

rp

rt Addendum circle radius (m)

pC
t
2

t Tooth thickness (m)

Gear Nomenclature
Example 2
A spur gear with 35-teeth, 100-mm pitch circle diameter and 20 pressure
angle is being optimized with its geometry figure. Determine:
a)Addendum, a
b)Dedendum, b
c)Base circle radius, rb
d)Addendum circle radius, rt
e)Dedendum circle radius, rr
f)Tooth thickness, t

Gear Nomenclature
Example 2
A spur gear with 35-teeth, 100-mm pitch circle diameter and 20 pressure
angle is being optimized with its geometry figure. Determine:
a)Addendum, a
b)Dedendum, b
c)Base circle radius, rb
d)Addendum circle radius, rt
e)Dedendum circle radius, rr
f)Tooth thickness, t

(a = 0.0029m)
(b = 0.0036m)
(rb = 0.047m)
(rt = 0.0529m)
(rr = 0.0464m)
(t = 0.0045m)

Gear Nomenclature
Torque & Efficiency
The power transmitted by a torque T (N-m) applied to a shaft rotating at n
rev/min is given by:

2 n T
P
60
In an ideal gear box, the input and output powers are the same so;

2 .nPTP 2 .nGTG
P

60
60
TG nP
nPTP nGTG

GearRatio
TP nG

Gear Nomenclature
Example 3
Engine-Pump mechanism below show few gears meshing with different
parameters as shown below. Given: n1 = 500 rpm; N1 = 20; N2 = 70; N3
= 18; N4 = 54
Find:

(a) n4
(b) Torque and power changes at Gear 4
n4, N4
Engine

n1, N1
Pump
n2, N2
n3, N3

Gear Nomenclature
Example 3
Engine-Pump mechanism below show few gears meshing with different
parameters as shown below. Given: n1 = 500 rpm; N1 = 20; N2 = 70; N3
= 18; N4 = 54
Find:

(a) n4
(b) Torque and power changes at gear no. 4

Solution:
(a) n2 = 500 rpm*(20/70) = 142.8 rpm
n3 = n2
n4 = 142.8 rpm*(18/54) = 47.6 rpm
(b) Total reduction = 500/47.6 = 10.5 (0r 10.5:1)
Torque = Increases by 10.5
Power = Stays the same throughout

Gear Nomenclature
Example 4
Gear

Engine
Output
Torque

Engine
Speed

Gear
Ratio

200 N.m

2000
RPM

4:1

200 N.m

2000
RPM

2:1

200 N.m

2000
RPM

1:1

200 N.m

2000
RPM

0.5:1

Transmission Transmission Transmission

Output Torque Output Speed Form

Gear Nomenclature
Example 4
Gear

Engine
Output
Torque

Engine
Speed

Gear
Ratio

Transmission Transmission Transmission

Output Torque Output Speed Form

200 N.m

2000
RPM

4:1

800 N.m

500 RPM

Underdrive

200 N.m

2000
RPM

2:1

400 N.m

1000 RPM

Underdrive

200 N.m

2000
RPM

1:1

200 N.m

2000 RPM

Direct Drive

200 N.m

2000
RPM

0.5:1

100 N.m

4000 RPM

Overdrive

Gear Nomenclature
Torque & Efficiency
It follows that if the speed is reduced, the torque is increased and vice
versa. In a real gear box, power is lost through friction and the power
output is smaller than the power input. The efficiency is defined as:

Power out
2 nG TG 60

.100%
.100%
Power In
2 nP TP 60
nG TG

.100%
nP TP
The total torque must add up to zero:
T1 + T2 + T3 = 0

Gear Nomenclature
Example 5
A gear box has an input speed of 1500 rev/min clockwise and an
output speed of 300 rev/min anticlockwise. The input power is 20
kW and the efficiency is 70%. Determine:
i. The gear ratio;
power.;
iv. The output torque;

Solution :

ii. The input torque.;

iii. The output

v. The holding torque.

G1

G3
Input speed
nP 1500
i ) G.R or VR

5 5 :1
Output speed nG 300

2 nPTP
60 Input Power
TP
60
2 nP
60 20000
Input torque TP
127.3 N . m
2 1500
( Negative clockwise)

ii ) Input Power

G2

Gear Nomenclature
Example 5

Output power
iii ) 0.7
,
Input power
Output power 0.7 20000 14000W 14kW
60 14000
iv) Output torque TG
445.6 N . m
2 300
Positive anticlockwise

v) T1 T2 T3 0
127.3 445.6 T3 0
Holding torque , T3 127.3 445.6 318.3 N . m
( Negative Clockwise)

Other Drives

Splitter One input with several outputs

Right Angle Transfers torque thru right
angles, can be as simple as mating bevel
gears

www.gamweb.com/ power_series.htm

Types of Gear Boxes: http://en.wikipedia.org/wiki/Gear_box

Other Drives

Differentials
Engines typically operate over
a range of 600 to about 7000
revolutions per minute (though
this varies, and is typically less
for diesel engines), while the
car's wheels rotate between 0
rpm and around 1800 rpm.
Engine: higher speed, lower
torque versus wheels.

www.torsen.com/products/ T-1.htm
How a manual transmission works: http://en.wikipedia.org/wiki/Manual_transmission

Transfer of energy is accomplished through three basic means:

The gear, the belt, and the chain.
Statics deals with forces and their effect on a body at rest.
Dynamics is the study of force as it works on a rigid body in
motion.

TRANSFER OF ENERGY FROM THE MOTOR TO THE END EFFECTOR

John Deere 3350 tractor cut in Technikmuseum Speyer

Gears vs Belts and Chains

Gears are much more capable in terms of

power rating (helical gear drives capable of
> 30,000 hp)
With planetary gear sets large gear ratios
can be achieved (100:1)
Gear applications include high torque and
high speeds
Can have multiple speed reductions by
pairing different gears or gear trains
(several gears in series)

Gear Trains
Introduction

A gear train is two or more gear working together

by meshing their teeth and turning each other in a
system to transmit torque, power and speed

It reduces speed and increases torque

Electric motors are used with the gear systems to

reduce the speed and increase the torque

Gear Trains
Types
Simple gear train
Compound gear train
Epicyclic / Planetary gear
train

Gear Trains
Simple Gear Train

The most common of the gear train is the gear pair

connecting parallel shafts. The teeth of this type can
be spur, helical or herringbone.
Only one gear may rotate about a single axis

Gear Trains
Compound Gear Train

For large velocities,

compound arrangement
is preferred

Two or more gears may

rotate about a single
axis

Driver

Driven

Compound
Gear

Gear Trains
Epicyclic / Planetary Gear Train

Simple planetary gearsets contain three

components

Internal (ring) gear / (annulus gear)

Planet gears (and carrier)
Sun gear

One component will be the drive member,

one the driven, and one will be held
(except direct drive and neutral)
Unlike other types of gears, planetary
gears are able to operate on one single
axis

Gear Trains
Epicyclic / Planetary Gear Train

Direct Drive

Any two of the components are driven

1:1 Ratio

Gear Trains
Epicyclic / Planetary Gear Train

Underdrive

Planet carrier is the output

Minimum reduction

Ring gear is held

Sun gear is the input

Maximum reduction

Ring gear is input

Sun gear is held

Gear Trains
Epicyclic / Planetary Gear Train

Overdrive

Planet carrier is the input

Minimum overdrive

Ring gear is the output

Sun gear is held

Maximum overdrive

Ring gear is held

Sun gear is the output

Gear Trains
Epicyclic / Planetary Gear Train

Reverse

Planet carrier is held

Underdrive

Ring gear is the output

Sun gear is the input

Overdrive

Ring gear is the input

Sun gear is output

Gear Trains
Epicyclic / Planetary Gear Train

Planetary gear sets is that they can produce different

gear ratios depending on which gear you use as the
input, which gear you use as the output, and which one
you hold still

Popular used in automatic transmissions in automobiles

Also used in bicycles for controlling power of pedaling

automatically or manually

And also used for power train between internal

combustion engine and an electric motor

Gear Trains
Epicyclic / Planetary Gear Train
Sun

Carrier

Internal

Speed

Torque

Direction

Input

Output

Held

Maximum
Reduction

Maximum
Increase

Same as
Input

Held

Output

Input

Minimum
Reduction

Minimum
Increase

Same as
Input

Output

Input

Held

Maximum
Increase

Maximum
Reduction

Same as
Input

Held

Input

Output

Minimum
Increase

Minimum
Reduction

Same as
Input

Input

Held

Output

Reduction

Increase

Opposite as
Input

Output

Held

Input

Increase

Reduction

Opposite as
Input

Gear Trains
Epicyclic / Planetary Gear Train

Gear Trains
Epicyclic / Planetary Gear Train

Gear Trains
Epicyclic / Planetary Gear Train

Direct Drive = 1:1

Underdrive

Carrier is output

# of sun gear teeth + #of ring gear

teeth
#
of teeth on the driving member

=
Ratio

Gear Trains
Epicyclic / Planetary Gear Train

Overdrive

Carrier is input

# of teeth on the driven member =

# of sun gear teeth +
Ratio
#of ring gear teeth

Gear Trains
Epicyclic / Planetary Gear Train

Underdrive

Carrier is held

# of teeth on driven gear_ =

# of teeth on driving
Ratio
gear