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Gear Drives
Gears are toothed, cylindrical wheels used for transmitting
motion and power from one rotating shaft to another
Usually used to decrease speed and increase torque from
the input to output shaft.
Highly efficient with output power approximately equal to
input power
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Gear Drives are Fixed Transmissions
All components are rigidly mounted to fixed
shafts, usually inside a sealed housing.
Alignment is critical.
Speed reduction ratio, np/ng = Ng/Np
Torque increase ratio = 1/speed reduction ratio
Pinion attaches to input shaft, has Np
number of teeth and rotates at speed np
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Applications for Gear Drives
Very large increases in torque from very high speed, low torque
power sources, accomplished in a tight package space. Best known
application is the transmission for gas powered autos
Change in direction of rotation speed. Used in differential for rear-
wheel drive, gas powered cars From drive shaft connected To rear wheel
to Transmission (2x)
Differential
Image source: www.wisegeek.com Transmission
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https://d2t1xqejof9utc.cloudfront.net/screenshots/pics/34
798f21a8b3f44d2aa2b9b7d1722956/medium.gif
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Types
of Gears
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How a Spur Gear Drive Works
As the input and
output shafts
rotate, the teeth
engage and the
input teeth push
on the output
teeth in a
direction
tangential to the
Speed reduction
axis of rotation.
ratio = Ng/Np =
11/18 = .61
https://en.wikipedia.or
g/wiki/Gear
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Advantages of a Gear Drive
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Gear Geometry: The Involute Curve
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Gear Tooth Geometry
Pitch Circle : theoretical
circle upon which the
involute curves are built.
Pitch Diameter, D : The
diameter of the pitch
circle.
Circular Pitch, p : The
circumferential distance
on the pitch circle, from a
point on one tooth to the
corresponding point on
the adjacent tooth.
Pitch of the two gears in
mesh must be identical
Addendum, a: Radial distance between top land and pitch circle.
Dedendum, b: Radial distance from bottom land to pitch circle.
Face: Thickness of the tooth
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Spur Gear Geometry Equations
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Pressure Angle
Surface of
gear tooth Tangent to
pitch circles
Line drawn
to surface
of gear
tooth
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Changing the Pressure Angle Changes
the Shape of the Gear Tooth
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Contact Ratio Indicates Minimum Number of
Teeth in Contact at any Time
mf must be >1.2,
with typical spur
gears around 1.5
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Gear Geometry Problem Number 2 with
Two Gears, Instead of One Gear
g and Np = 17
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Solution to Gear Geometry Problem Number 2:
Use Table 8-1 formulae
Problem number: 8-2 with two gears
Input data:
Gear Number of teeth: N g = 34
Pinion Number of teeth: N p = 16
Diametral pitch: P d = 24
Pressure angle: f = 20 degrees
(o) Radius of base circle for Gear: R bG = 0.6656 in RbG = (Dg/2) x cos ()
(p) Radius of base circle for pinion: R bP = 0.3132 in RbP = (Dp/2) x cos ()
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How a Helical Gear Drive Works
Pros:
Runs very quietly due to a tooth assuming load gradually as the
gears rotate, rather than all at once
Greater strength for the same size gear.
Cons:
Greater cost than spur gears
Introduces axial component of force on the mating shaft, and
requires thrust bearings to support the force
https://grabcad.com/library/helical-gear-with-involute-teeth-profile-1
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Primary Helical Gear Forces
Tangential force Wt
acts tangential to the
pitch surface and to
the shaft axis
Radial force Wr acts
towards the center of
the mating gears,
tending to push them
away from each other
Axial force Wx acts
parallel to the shaft,
also known as the
thrust force
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Primary Helical Gear Angles and Planes
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Helical Gear Diametral Pitch
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Helical Gear Metric Module
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Helical Gear Metric Module
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Helical Gear Geometry Problem Number 41
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Solution to Problem Number 41
Input data:
Number of teeth: N = 45
Transverse Diametral pitch: P d = 8
Transverse Pressure angle t 14.5 degrees
Helix angle: y = 30 degrees
Degrees per Radian = 57.296 degrees
Face width: w = 2 inches
(f) Normal Pressure angle n = 12.624 degrees tan-1 ( tan (t) cos(y))
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Other Types of Bevel Gears
Spiral Gear: Teeth are angled with
respect to axis at a spiral angle, just
like helical gear. Low vibration, low
noise at high speeds. Thicker teeth
in direction of loading allows the
Image source: www.dir.indiamart.com gear to carry heavier loads than a
straight bevel gear.
Hypoid Gear: Teeth are angled and
spiral, but the main axes do not
intersect. Used for quiet action & to
save space
Image source: www.greenfries.info
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Table 8-8 Has the Kinematic Formulae for
Straight Bevel Gears
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Table 8-8 Has the Kinematic Formulae for
Straight Bevel Gears
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Google Image Drawings Showing Dimensions
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Google Image Drawings Showing Dimensions
(Pd = 6)
(Pd = 8)
(Pd = 10)
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Image source: www.matinproucts.com
Bevel Gear Geometry Problem Number 45
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Solution to Bevel Gear Geometry Problem Number 45
PROBLEM: 45
GIVEN DATA Variable
No of teeth in pinion = 15 NP
No of teeth in gear = 45 NG
Diametral pitch = 6 Pd
Pressure angle = 20 degrees (usually fixed at 20)
2 Worm Gear
Drives move
these pen
mechanisms back
and forth across
the paper, as
temperature and
Paper humidity change
Rotates 360
in 1, 7 or 31
days
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2/1/2017 Image source: www.omega.com
Pros and Cons of a Worm Gear Drive
Pros
Very large gear ratios (up to about 360:1) in a compact package,
because of the small number of teeth on the worm.
If the lead angle of the worm is small enough (< about 6 degree)
the worm set can be self-locking, i.e., it cannot be back-driven
from the worm gear so that it will hold a load.
Locking action is produced by friction between worm threads
and the worm gear teeth
Cons
Relatively low efficiency compared to other gear sets.
The sliding (not rolling) motion between the teeth generates
significant heat.
Heat in a gearbox, not stresses in the teeth, limits a worm sets
life.
For high power applications, the oil temperature in the gear box
should be kept below about 200 degree Fahrenheit for long
45 tooth life. 2/1/2017
Worm Gear Motion
http://forums.autodesk.com/autodesk/attachments/a
utodesk/12/141661/1/Worm%20Gear.gif
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Worm Gear Geometry Equations
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Worm Gear Motion Equations
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Worm Gear Dimensions
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Worm Gear Geometry Problem Number 52
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Solution to Worm Gear Geometry Problem Number 52
Wormgearing - Design Problem 52
Input Data:
No. of worm threads: NW = 1
Pitch diameter: D w= 1.250 in
Diametral pitch: Pd = 10
Normal pressure angle: fn = 14.5 degrees
Specify No. of gear teeth: NG = 40
Nominal gear face width: F eG = 0.625 in
Calculated Data: Formula
Axial pitch of worm: px = 0.314 in px = p
Lead of the worm: L= 0.314 in L = NW px
Circular pitch: p = 0.314 in p = /Pd
Lead angle: l= 4.574 deg l = tan-1 (L/ Dw
Addendum: a= 0.100 in a = 1/Pd
Dedendum: b= 0.116 in b = 1.157/Pd
Worm outside diameter: D oW = 1.450 in DoW = Dw + 2a
Worm root diameter: D RW = 1.019 in D RW = D w - 2b
Gear pitch diameter: DG = 4.00 in D G = N G/P d
center distance: C= 2.625 in C = (Dw + DG)/2
velocity ratio: VR = 40.00 VR = NG / NW
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Velocity Ratio and Gear Trains
Velocity Ratio = in / out
Substituting for radii,
diameters or speed in
RPM gives other equations
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Gear Trains Have a Rotation Direction
Change at Each Stage
www.technologystudent.com
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Train Value
Use Train value (TV)
when more than two
gears are in mesh
TV = (VR1)VR2) = (NBND)/(NANC)
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TV = (70)(54)/(20)(18) = 10.5
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Idler Gears
Idler Gear: Any gear that performs as both a driving and driven
gear
Idler gears are used to fill a void between two gears when it is
not possible to bring their two shafts closer enough together to
meet the center distance requirement
Idler gears do not affect the TV, as the number of teeth appear
in the numerator and denominator of the TV equation
Idler gears cause 2 rotation direction reversals that cancel out
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2/1/2017 Image source: www.imgarcade.com
Internal Gear
Internal Gear: teeth are machined on the inside of a ring,
instead of on the outside of a gear blank
The gear rotates in the same direction as the pinion
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2/1/2017 Image source: www.cogmatic.com
Internal Gears are Used in Tight Spaces Where
Rotation Direction Must Remain the Same
www.softdevspb.com
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Rack and Pinion
Rack and Pinion Gear Set: The gear (i.e. rack) has infinite
radius, so that it is flat
Used in car steering mechanisms
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2/1/2017 Image source: www.cogmatic.com
Rules for Creating a Gear Train
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Rules for Creating a Gear Train
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Three Methods of Designing a Gear Train
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Complex Gear Geometry Problem Number 58
Idler Gear
Shaft (6x)
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Solution to Complex Gear Geometry Problem Number 58
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Kinematic Design Gear Trains Problem 67
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Step by Step Procedure to Solve Problem 67
1. Use the Residual Ratio method. Use spur gears, as they are
the simplest and lowest cost gears for parallel shaft.
2. Nominal train value (TV) = 1800/21.5 = 83.7
3. From Table 8-7, if we use at least 17 pinion teeth, we can go
up to 1309 teeth with no interference. This is no problem, as
we are limited to 150 teeth max on any one gear
4. VRMAX per gear/pinion pair = 150/17 = 8.83
5. Suppose we did two gear/pinion pairs. The VR = 8.832 = 77.85
6. Because 77.85 < 83.7, we will need to use three pinion/gear
pairs
7. Lets try having three equal TVs. Then TV = 83.701/3 = 4.37
8. Now we must make sure that the number of teeth in any
gear be an integer (Rule 2), so we cant use 4.37
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Step by Step Procedure to Solve Problem 67
9. Lets try using TVs near 4.37, like 4 or 5. This way we can
pick the number of pinion teeth and know that the
mating gear will have an integer number of teeth
10. In order to keep TV for the system at 83.7, we want to
alternate the individual TVs. Lets start with 5, then 4,
and see what last TV we need to get to 83.7
11. To keep the gear train compact, lets make the pinion
gears have 17 teeth each, the minimum needed to
prevent interference
12. Then NA = 17 and NB = 17 x 5 = 85.
13. Then NC = 17 and ND = 17 x 4 = 68.
14. The TV for two pinion/gear pair is 4 x 5 = 20
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Step by Step Procedure to Solve Problem 67
15. Which means that the TV for the third pair = 83.7/20 =
4.19
16. Then NE = 17 and NF = 17 x 4.19 = 71.23
17. Then we must round NF to nearest integer. NF = 71. So
the actual TV of the third stage = 71/17 = 4.18
18. Lets calculate the revised system TV and output rpm.
19. TV = 4 x 5 x 4.18 = 83.53
20. Output rpm = 1800/83.53 = 21.55, which is between 21
and 22
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Solution to Problem 67