MECHANICAL ENGINEERING DESIGN 1

MEC 531
Part B:
Design of Machine Elements
By:
NURZAKI IKHSAN
Chapter Outline


6.1 Gears
6.2 Parallel & non-Parallel Shaft





Chapter 6:
Design of Power Transmission
Introduction
Gear is a mechanical element/component by which a power can be
transmitted from one shaft to another.
Types of gear:
1. Spur gears
2. Helical gears
3. Bevel gears
4. Worm gears
Parallel shaft spur gears & helical gears.
Perpendicular two intersecting shaft bevel gears & worm gears.
Spur Gears
Teeth parallel to the axis of rotation.
Used to transmit motion from one
shaft to another, parallel, shaft.
Spur gear is the simplest and, for this
reason, will be used to develop the
primary kinematic relationships of
the tooth form.
Helical Gears
Teeth inclined to the axis of rotation.
Can be used for the same applications as spur gears.
Not noisy, because of the more gradual engagement of the teeth during
meshing.
The inclined tooth also develops thrust loads and bending couples, which
are not present with spur gearing.
Helical gears are used to transmit motion between parallel and sometimes
are used to transmit motion between nonparallel shaft.
Bevel Gears
Teeth formed on conical surfaces and
are used mostly for transmitting
motion between intersecting shafts.
Three types:
1. Straight-tooth bevel gears
2. Spiral bevel gears
3. Hypoid gears
Worm Gears
Worm gear sets are used to transmit rotary
motion between nonparallel and
nonintersecting shafts.
Direction of rotation of the worm gear
depends upon the direction of rotation of the
worm and upon whether the worm teeth are
cut right-hand or lefthand.
Made so that the teeth of one or both wrap
partly around the other.
Two types:
1. Single-enveloping worm-gear sets.
2. Double-enveloping worm-gear sets.
Mostly used when the speed ratios of the two
shafts are quite high 3 or more.
Nomencluture
Pitch circle a theoretical circle upon which all calculations are usually based.
Pitch diameter diameter of pitch circle.
Module, m ratio of the pitch diameter to the number of teeth.
Circular pitch, p distance, measured on the pitch circle, from a point on one
tooth to a corresponding point on the next tooth. (tooth thickness + width of
space)
Nomencluture
Addendum, a radial distance between the top land and the pitch circle.
Nomencluture
Dedendum, b radial distance from the bottom land to the pitch circle.
Whole depth, ht = Addendum, a + Dedendum, b
Nomencluture
Clearance circle circle that is tangent to the addendum circle of the mating
gear.
Nomencluture
Clearance, c the amount by which the dedendum in a given gear exceeds the
addendum of its mating gear.
Nomencluture
Gears Relationship
Relations between the previous nomenclatures:
Where;

P = diametral pitch, teeth per inch
N = number of teeth
d = pitch diameter, in
m = module, mm
d = pitch diameter, mm
p = circular pitch
Gears Relationship
Example
An 18-tooth pinion is to mesh a 30-tooth gear. Given that the module of
the gear set is 12 mm/teeth. Determine the pitch diameter for the
pinion and gear.
CONSTRUCTING GEARS
Learning how to construct and draw the teeth on a pair of meshing gears is not for
manufacturing or shop purpose
More to obtain an understanding of the problems involved in the meshing of the
mating teeth.
Take previous examples pitch diameters to start constructing our gear.
Constructing Involute Curve
1. Divide the base circle into a number of
equal parts and construct radial lines.OA0,
OA1, OA3, etc.
2. At OA1, construct perpendicular lines A1B1,
A2B2, A3B3, etc.
3. Mark the distance between A1A0 along
A1B1, twice along A2B2 and so on producing
points.
4. Connect the points to construct the
involute curve.
Steps to Construct a Gear
1. Known that the pinions pitch diameter is 216 mm and gears diameter is
360 mm. Center distance;


2. Locate pinion and gear centers O1 and O2 at 288 mm apart.
3. Construct pitch circles of pinion, r1=108 mm and pitch circles of gear, r2=180
mm radii.
4. Locate pitch point (contact of the circles) that are tangent at P.
5. Draw a line, ab through the pitch point, P tangent to the circles. Gear 1 will
act as the pinion (driver rotating counter-clockwise) and gear 2 as the gear.
6. Draw a line, cd (pressure line or generating line or line of action) through
the pitch point, P at an angle to the common tangent. Angle (pressure
angle) values of 20
o
or 25
o
.
Static Loading Example
7. On each gear, draw circle tangents (base circles) to the pressure line, cd. The
pressure angle, determines their size.
8. Radius of the base circle;
9. Generate an involute on each base circles. Draw the addendum and
dedendum;

10. To draw a tooth, the tooth thickness, t must be known. Tooth thickness is
given as;


11. Determine the clearance, c = b a, The fillets of the teeth is taken from the
above clearance, c.

* To draw the actual shape of the gear teeth, a template for drawing gear teeth is
needed and may not be the same depending how the profile is generated.

Example
A gearset consists of a 16-tooth pinion driving a 40-tooth gear. The diametral
pitch is 2 and the addendum and dedendum are 1/P and 1.25/P respectively.
The gears are cut using a pressure angle of 20
o
.

a) Compute the circular pitch, the center distance and the radii of the base
circles.

b) In mounting these gears, the center distance was incorrectly made . in
larger. Compute the new values of the pressure angle and the pitch-circle
diameters
Contact Ratio
Tooth contact begins and ends at the intersections of the two addendum circles with
the pressure line.
When a tooth is just beginning contact at a, the previous tooth is simultaneously
ending its contact at b.
Contact ratio can be defined as;
Where;

qt = arc of action
qr = arc of recess
qa= arc of approach

This ratio is equal to the length of the path of contact between the teeth divided by
the base pitch.
Contact ratio for gears should not be less than 1.20 inaccuracies in mounting might
reduce the contact ratio, therefore may increase impact of teeth and generate noise.
Forming Of Gear Teeth
Ways of forming teeth of gears may vary from:
Sand casting Permanent-mold casting
Die casting Shell molding
Centrifugal casting Investment casting
Powder metallurgy process Extrusion process
Cold forming or cold rolling

Gear teeth may be machined by milling, shaping, or hobbing.
They may be finished by shaving, burnishing, grinding, or lapping.
Gears made of thermoplastics such as nylon,n polycarbonate, acetal
are quite popular and are easily manufactured by injection molding.
Are low to moderate precision, low in cost for high production
quantities, and capable of light loads, an run without lubrication.
Milling
Gear teeth may be cut with a form milling cutter shaped to conform to
the tooth space.
Need to use a different cutter for each gear because a gear having 25
teeth, for example, will have a differentshaped tooth from one having,
say, 24 teeth.
A separate set of cutters is required for each pitch
Forming Of Gear Teeth
Shaping
Teeth may be generated with either a pinion cutter or a rack cutter.
The pinion reciprocates along the vertical axis and is slowly fed into
the gear blank to the required depth.
When the pitch circles are tangent, both the cutter and the blank
rotate slightly after each cutting stroke.
Since each tooth of the cutter is a cutting tool, the teeth are all cut
after the blank has completed one rotation.
Forming Of Gear Teeth
Hobbing
The hob is simply a cutting tool that is shaped like a worm.
The teeth have straight sides, as in a rack, but the hob axis must be turned
through the lead angle in order to cut spur-gear teeth.
For this reason, the teeth generated by a hob have a slightly different shape
from those generated by a rack cutter.
Both the hob and the blank must be rotated at the proper angular-velocity ratio.
The hob is then fed slowly across the face of the blank until all the teeth have
been cut.
Forming Of Gear Teeth
Gear Trains
Speed of a pinion 2 driving a gear 3 is given by:



Where n = revolutions or rev/min
N = number of teeth
d = pitch diameter
Above equation applies to any gearset spur, bevel, helical or worm.
Absolute value user can define positive or negative gear rotation
direction.
But for spur and parallel helical gears positive for counterclockwise
rotation.
Driven Gears Speed
The speed of the above driven gear 6 is given as:



No ratio between N4 and N5 because the gears attached to each
other.
For spur gears, e is positive if the last gear rotates in the same way
as the first gear.
Train value, e is defined as:



Product of either driving or driven tooth numbers:
Number of teeth, N
Pitch diameters, d
Relation between the speed of the last gear and the first gear in
the train:
Driven Gears Speed
Example
A 17-tooth spur gear (pinion) with a diametral pitch, P of 8, n2 = 1120 rpm,
n3 = 544 rpm. Determine the number of teeth in the gear and center to
center distance between the gears.
FBD of Forces and Moments
Force Analysis-spur Gearing
Force Analysis-spur Gearing
Designation of gear will start with gear 2 as the input and then
number the gears successively 3, 4, etc until the last gear in the train.
Shafts will be designated as lowercase letters a, b, c, etc.
Force exerted by gear 2 against gear 3 F23
Force of gear 2 against a shaft a F2a
Radial component of force Fr
Tangential component of force Ft
Torque exerted by shaft a against pinion 2 Ta2
Transmitted load: or [kN]
Where H = power, kW
d = gear diameter, mm
n = speed, rev/s
Torque:

Power transmitted:
Gear data is often tabulated using pitch-line velocity, V


Where V = pitch-line velocity, mm/s
d = gear diameter, mm
n = gear speed, rev/s
Force Analysis-spur Gearing
Force Analysis-bevel Gearing
Transmitted load:



Other forces acting at the center of the tooth:
Force Analysis-helical Gearing
Three (3) components of the total
(normal) tooth force W:




If Wt is given:
Force Analysis-worm Gearing
Considering coefficient of friction, f :
Three (3) orthogonal components:
Efficiency of worm gearset:




Coefficient of friction is dependent on
the relative or sliding velocity, VS