Gear Design

Contents
• Introduction
• Types of gears
• Law of gearing
• Gear Tooth Profile
• Gear Terminologies
• Involute Profile
• Steps of gear design
• Spur Gear – Force Analysis
• Lewis Equation
• AGMA Equation
• Force analysis
– Helical gears
– Worm gears
– Bevel gears
Types of Gears
• Spur Gear
• Helical Gear
• Double Helical
• Straight bevel
• Spiral Bevel
• Hypoid Bevel
• Worm Gears
• Spiral gears
• Rack and Pinion
Spur Gear
Helical Gear
Double Helical Gear
Straight Bevel Gear
Spiral Bevel Gear
Hypoid Bevel Gear
Worm Gear
Spiral Gear
Rack and Pinion
Law of Gearing
• The angular velocity ratio between the gears
of a gear set must remain constant
throughout the mesh.
• The angular velocity ratio is equal to the ratio
of the pitch radius of the input gear to that of
the output gear.
Law of Gearing

v  ωr
mv = ωout/ωin ωin rin  ωout rout
= rin/rout

A gear set is device to exchange torque for velocity or

vice versa.
Gear tooth profile
• In order for the fundamental law gearing to be
true, the gear tooth contours on mating teeth
must be conjugates of one another.
• The involute tooth form is one common gear
tooth profile.
• Involute profile is achieved by unwrapping a
string from a circle
Gear tooth profile
Meshing action
Gear Terminology
Gear Terminology
• Circular Pitch,
• Diametral Pitch (in 1/inch), Module (in mm),
m=d/N
• Pitch surface : The surface of the imaginary
rolling cylinder (cone, etc.) that the toothed gear
may be considered to replace.
• Pitch circle: A right section of the pitch surface.
• Addendum circle: A circle bounding the ends of
the teeth, in a right section of the gear.
Gear Terminology
• 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 dedendum 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 surface.
Gear Terminology
• Circular thickness (also called the tooth thickness) : The
thickness of the tooth measured on the pitch circle. It is the
length of an arc and not the length of a straight line.
• Tooth space: The distance between adjacent teeth measured
on the pitch circle.
• Backlash: The difference between the circle thickness of one
gear and the tooth space of the mating gear.
• Circular pitch p: The width of a tooth and a space, measured
on the pitch circle. pc=pd/N
• Diametral pitch P: The number of teeth of a gear per inch of
its pitch diameter. The circular pitch, therefore, equals the
pitch circumference divided by the number of teeth.
pd=N/d=p/pc
Gear Terminology
• Module m: Pitch diameter divided by number of teeth. The
pitch diameter is usually specified in inches or millimeters; in
the former case the module is the inverse of diametral pitch.
• Fillet : The small radius that connects the profile of a tooth to
the root circle.
• Pinion: The smaller of any pair of mating gears. The larger of
the pair is called simply the gear.
• Velocity ratio: The ratio of the number of revolutions of the
driving (or input) gear to the number of revolutions of the
driven (or output) gear, in a unit of time.
• Pitch point: The point of tangency of the pitch circles of a pair
of mating gears.
Gear Terminology
• Common tangent: The line tangent to the pitch circle at the
pitch point.
• Line of action: A line normal to a pair of mating tooth profiles
at their point of contact.
• Pressure angle : The angle between the common normal at
the point of tooth contact and the common tangent to the
pitch circles. It is also the angle between the line of action and
the common tangent.
• Base circle :An imaginary circle used in involute gearing to
generate the involutes that form the tooth profiles.
Gear Terminology
Steps of designing a spur gear
In the design of gear drive, following data is
mostly given,
i. Shaft layout
ii. The power to be transmitted
iii. The speed of driver and driven gear (velocity
ratio)
iv. The center distance
Steps of designing a spur gear
By using the given data, we can design the gears,
i. The first step is to choose the appropriate type
of gears.
ii. Module/D.P and Pressure angle should be
selected.
iii. All the dimensions/sizing of gears are calculated
by using various gear formulae.
iv. Gear tooth profile (Involute profile) is drawn.
v. Force analysis is done.
vi. Analysis of designed gear.
Steps of designing a spur gear
Module Diametral Pitch
Gear tooth size varies Gear tooth size varies
directly with module inversely with D.P
Steps of designing a spur gear
Force analysis of Spur Gear
Force analysis of Spur Gear
Force analysis of Spur Gear
Force analysis of Spur Gear
P = Power to be transmitted;
T = Torque transmitted;
n = rpm;
d = pitch diameters;
Wt = Transmitted load;
Wr = Radial load;
W = Resultant load;

P = ωT Wr = Wt Tan α
P = (2πn/60) x (Wtd/2) W = Wt / Cos α
Wt = 60P/πdn
Force analysis of Spur Gear
• Even if the torque T is constant with time,
each tooth will experience repeated loading as
it comes through the mesh.
• Ma = Alternating B.M
• Mm = Mean B.M
• The bending moment-time function is shown
as;
Force Analysis-Time Varying Bending
Moments
Force analysis of Spur Gear
Problem
Stresses in Spur Gears
• There are two modes of failure that affect
gear teeth,
1. Fatigue failure (due to bending stresses)
2. Surface failure (due to surface stresses)
 Bending Stresses in Spur Gears
Lewis Equation: Bending stress equation in a gear tooth was
developed by W. Lewis in 1892,
 AGMA Bending Stress Equation
Assumptions:
Stresses in Spur Gears
• When a pair of gears is driven at moderate or
high speed, it is certain that dynamic effects
are present.

Velocity Factor= Kv = (1200 + V)/1200

where V is the pitch line velocity in feet per
minute.
Force Analysis – Helical Gears
• The circular pitch
p and pressure
angle ɸ are
measured in the
plane of rotation.
• Pn and ɸn are
corresponding
values in normal
plane.
 Force Analysis – Helical Gears
• Pn = P cos ψ
• Pa = P/tan ψ
• The relation
between normal
and transverse
pressure angle is;
tanɸn = tanɸ.cosψ
• (D.P)n = D.P/cosψ
• (m)n = m cosψ
 Force Analysis – Helical Gears
• Fr = Fn sinɸn
• Fr = Ft tanɸ
• Ft = Fn cosɸn cosψ
• Fa = Fn cosɸn sinψ
• Fa = Ft tanψ
1000 𝑃 (𝑘𝑊)
• Ft =
𝑉 (𝑚/𝑠)
33000 𝑃 (ℎ𝑝)
• Ft =
𝑉 (𝑓𝑡/𝑚𝑖𝑛)
 Force Analysis – Helical Gears
A 75 kW induction motor runs
at 740 rpm in clockwise
direction. A 19 tooth helical
pinion with 20˚ normal pressure
angle, 10 mm normal module
and a helix angle of 23˚ is keyed
to the motor shaft. Draw free
body diagram of the system,
showing all the forces on pinion
pitch surface and the bearings
at A and B. The thrust should be
taken out at A.
Worm Gear
Worm gear
 Force Analysis – Worm Gears
- Self-locking
- High gear
ratios
- Shape of tooth
is not involute
(variable
tangential
velocity)
Tan (lead angle) =
L/πd1
P = L/Nw
= Pc = πd2/Ng
 Force Analysis – Worm Gears
• F1t = F2a
• F1r = F2r
• F1a = F2t

33 000 𝑃 (ℎ𝑝)
• F1t =
𝑉𝑚(𝑓𝑡/𝑚𝑖𝑛)
Force Analysis – Worm Gears
Force Analysis – Bevel Gears
Force Analysis – Bevel Gears
33 000 𝑃(ℎ𝑝)
• Ft = 𝑽𝑎𝑣𝑔