Introduction

A gear is a rotating machine part having cut teeth, or cogs, which mesh with another toothed
part in order totransmit torque. Two or more gears working in tandem are called a transmission
and can produce a mechanicaladvantage through a gear ratio and thus may be considered a
simple machine.Geared devices can change the speed, magnitude, and direction of a
powersource. The most common situation is for a gear to mesh with another gear;however a
gear can also mesh a non-rotating toothed part, called a rack,thereby producing translation
instead of rotation.The gears in a transmission are analogous to the wheels in a pulley.
Anadvantage of gears is that the teeth of a gear prevent slipping.When two gears of unequal
number of teeth are combined a mechanicaladvantage is produced, with both the rotational
speeds and the torques of thetwo gears differing in a simple relationship.Gears are used
extensively for transmission of power. They find applicationin: Automobiles, gear boxes, oil
engines, machine tools, industrialmachinery, agricultural machinery, geared motors etc. To
meet the strenuousservice conditions the gears should have: robust construction, reliable
performance, high efficiency, economy andlong life. Also, the gears should be fatigue free and
free from high stresses to avoid their frequent failures. Thegear drives should be free form
noise, chatter and should ensure high load carrying capacity at constant velocityratio. To meet
all the above conditions, the gear manufacture has become a highly specialized field.
History
According to historical records, gears had started as far as 400 to 200 BC in ancient China. Until
the 17
th
century,people began to study that they can transfer the movement of the tooth shape. In the
18
th
century, after theindustrial revolution in Europe, gear drive has been used widely; first
development of cycloid gear and theninvolutes gear is, until the early 20th century, involutes
gear has play a dominant position in the application.
Classification
Gears mesh with each other toothed machine parts, its mechanical transmission and the
mechanical application of the field is extremely broad. Modern gear technology has been
achieved: the gear module O.004 ~ 100 mm; geardiameter from 1 mm to 150 m; transmission
power up to the 100 thousand kilowatts; speed up to hundreds of thousands of r / min;
maximum peripheral speed of 300 m / sec.
The composition generally gear teeth, alveolar, French side addendum circle, tooth root circle,
base circle, pitchcircle. Gear can be classified by gear shape, tooth shapes, tooth surface. Such
as gear tooth profile, including toothprofile curve, pressure angle, tooth height, and deflection.
On the above mentioned involute gear, it is relativelyeasy to manufacture, so the modern use
of gears, the involute gear absolute majority, while the cycloid gear andthe circular gear is
seldom used.
Process
Gear manufacturing can be divided into two categories namely forming and machining as
shown in flow chart.Forming consists of direct casting, molding, drawing, or extrusion of tooth
forms in molten, powdered, or heatsoftened materials and machining involves roughing and
finishing operations.
Materials used in gear manufacturing process

The various materials used for gears include a wide variety of cast irons, non ferrous material
&non - materialmaterials the selection of the gear material depends upon:i.

Type of serviceii.

Peripheral speediii.

Degree of accuracy requirediv.

Method of manufacturev.

Required dimensions & weight of the drivevi.

Allowable stressvii.

Shock resistanceviii.

Wear resistance.1.
Cast iron is popular due to its good wearing properties, excellent machinability & Ease of
producingcomplicated shapes by the casting method. It is suitable where large gears of
complicated shapes areneeded.2.

Steel is sufficiently strong & highly resistant to wear by abrasion.3.

Cast steel is used where stress on gear is nigh & it is difficult to fabricate the gears.4.

Plain carbon steels find application for industrial gears where high toughness combined with
highstrength.
5.

Alloy steels are used where high tooth strength & low tooth wear are required.6.

Aluminum is used where low inertia of rotating mass is desired.7.

Gears made of non -Metallic materials give noiseless operation at high peripheral speeds.