MECHANICAL ENGINEERING DEPARTMENT LOGO

Machine Design & CAD - II

GEAR DESIGN PROJECT

Rack & Pinion Gear Design

GROUP MEMBERS
Khalil Raza Bhatti 07ME40 GL Waqas Ali Tunio
07ME34 AGL
Ayaz Ali Soomro 07ME31 Waqar Ahmed Bhutto
07ME36
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Contents

1 Introduction

2 Design Methodology

3 Design Consideration

4 Design Calculation

5 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 Helical teeth

or or
Spur Type Helical Type
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Design Requirements

Basic Design Characteristic

Speed
Effort

Force
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
 θ = pressure angle
 Fn = Ft tan θ
 Fr = Ft/Cos θ
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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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