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Standards Addressed
National Council of Teachers of English Standards (http://www.readwritethink.org/standards/index.html )
Students adjust their use of spoken, written, and visual language (e.g., conventions, style,
vocabulary) to communicate effectively with a variety of audiences and for different purposes.
Students conduct research on issues and interests by generating ideas and questions, and by
posing problems. They gather, evaluate, and synthesize data from a variety of sources (e.g., print
and non-print texts, artifacts, people) to communicate their discoveries in ways that suit their
purpose and audience.
Students participate as knowledgeable, reflective, creative, and critical members of a variety of
literacy communities.
Students use spoken, written, and visual language to accomplish their own purposes (e.g., for
learning, enjoyment, persuasion, and the exchange of information).
(9-12 ) Science and Technology Standards (from the National Science Standards web page)
http://www.nap.edu/readingroom/books/nses/html/6a.html#unifying
The abilities of design. Using math to understand and design gear forms is an example of one
aspect of an ability to design.
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Terms
Active Profile
Addendum
Backlash
Base Circle
Center Distance
Chordal Thickness
Circular Pitch
Circular Thickness
Dedendum
Diametral Pitch
Gear Ratios
Herringbone Gears
Idler Gear
Involute
Module
Pitch
Pitch Diameter
Pitch Point
Pressure Angle
Profile
Rack
Spur Gear
Velocity
Whole Depth
Working Depth
Materials/Equipment/Supplies/Software
Pencils
8-1/2 x 11 Paper
Compass
Protractor
Ruler
Straight Edge
1-2 String
Tin Can
Tape
GEARS-IDS Kit
GEARS-IDS Optional Gear Set
Objectives.
Students who participate in this unit will:
1. Sketch and illustrate the parts of a spur gear.
2. Calculate gear and gear tooth dimensions using gear pitch and the number of teeth.
3. Calculate center to center distances for 2 or more gears in mesh.
4. Calculate and specify gear ratios.
GEARS Educational Systems 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com
GEARS Educational Systems 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com
PD =
N
P
PD = Pitch Diameter
N = Number of teeth on the gear
P = Diametral Pitch (Gear Size)
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The pitch circle is the geometrical starting point for designing gears and gear trains. Gear trains
refer to systems of two or more meshing gears. The pitch circle is an imaginary circle that
contacts the pitch circle of any other gear with which it is in mesh. See fig. 6.3.1.5 below.
The pitch circle centers are used to ensure accurate
center-to-center spacing of meshing gears. The
following example explains how the center
distances of meshing gears is determined using the
pitch circle geometry.
Example 6.3.1.1
Calculate the center-to-center spacing for the 2
gears specified below.
Gears: Gear #1) 36 tooth, 24 Pitch Drive Gear
Gear# 2) 60 tooth, 24 Pitch Driven Gear
Step 1.) Calculate the Pitch Diameter for each of the two gears listed above.
N 36
=
= 1.5" Pitch Dia. = 1.5
P 24
N 60
Pitch Diameter (d) of gear#2 is:
D=
=
= 2.5" Pitch Dia. = 2.5
P 24
Step 2.) Add the two diameters and divide by 2.
D=
1.5
+ 2.5
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Term
Definition
Calculation
D=
Dedendum (B)
N
P
N
D
1
A=
P
1.157
B=
P
N +2
OD =
P
N 2
RD =
P
P=
BC = D * Cos PA
CP =
T=
3.1416 D 3.1416
=
N
P
3.1416 D 1.57
=
P
2N
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Addendum (A)
The addendum refers to the distance
from the top of the tooth to the Pitch
circle
Dedendum (B)
The Dedendum refers to the distance
from the Pitch circle to the root
circle.
Clearance (C)
Refers to the radial distance between
the top and bottom of gears in mesh.
Some machinists and mechanics
refer to clearance as play or the
degree of looseness between mating
parts.
14.5-degree tooth forms were the original standard gear design. While they are still widely
available, the 20-degree PA gear tooth forms have wider bases and can transmit greater loads.
Note: 14.5-degree PA tooth forms will not mesh with 20-degree PA teeth. Be certain to verify the
Pressure angle of the gears you use
Center Distance
The center distance of 2 spur gears is the distance from the center shaft of one spur gear to the
center shaft of the other. Center to center distance for two gears in mesh can be calculated with
PD gearA + PD gearB
this formula. Center-to-Center Distance =
2
Rotation
Spur gears in a 2-gear drive system (Gear #1 and Gear #2)
will rotate in opposite directions. When an intermediary
gear set or idler gear is introduced between the two gears
the drive gear (Gear #1) and the last gear (Gear #3) will
rotate in the same direction.
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Fig. 6.3.1.7b Rotation of Three Gear Drive
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Ratios
Gears of the same pitch, but differing numbers of teeth can be paired to obtain a wide range of
Gear Ratios. Gear Ratios are used to increase mechanical advantage (torque) or increase
rotational speed or velocity.
The ratio of a given pair of spur gears is calculated by dividing the number of teeth on the driven
gear, by the number of teeth on the drive gear.
The gear ratio in fig. 6.3.1.9 shows a 36 tooth gear driving a 60 tooth gear. The gear ratio can be
calculated as follows;
DrivenGearTeeth
DriveGearTeeth
60
GearRatio =
= 1.6 : 1
36
GearRation =
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GearRatio =
DrivenGearTeeth
DriveGearTeeth
36
= 0.66 : 1 = 1 : 1.66
60
Velocity
Velocity refers to the rotational speed of a gear and can be expressed using a variety of units. In
the examples that follow we will express gear velocity in inches per minute. The gear industry
often uses feet per minute. Inches per minute can be converted to feet per minute by simply
dividing by 12.
Velocity is expressed as the distance a point along the circumference of the pitch circle will
travel over a given unit of time.
Velocity can be calculated using this formula
Velocity = Pitch Circle Circumference x RPM
Example
The 24 pitch drive gear in fig 6.3.1.10 is turning at 100 rpm. What is the velocity of the drive
gear?
# Teeth N 60
D=
=
=
= 2.5"
Step 1.)
Determine the Pitch Diameter (D)
Pitch
P 24
Step 2.)
Determine the circumference of the Pitch Circle using the Pitch Diameter.
Circumference = D = 3.1416 2.5" = 7.854"
Step 3.)
Calculate the gear velocity using the gear velocity formula.
Velocity = 7.854 x RPM = 785.4 inches per minute or 65.45 ft per second.
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Step 2.)
Step 3.)
Step 4.)
D=
Compare the Velocity in feet per second of the two gears. The velocity of the 60-tooth drive
gear is 65 ft. per minute, AND the velocity of the 36-tooth driven gear is 65 feet per minute.
Gears in mesh rotate at different RPM but always at the same velocity. If this were not true,
then the teeth of the gears would strip off!
Calculating Ratios For Gear Trains with Multiple Gears
The preceding gear ratio problems dealt with two gears, or two gears and an Idler gear. An Idler
gear does not affect the overall ratio between the two adjacent gears. The Idler gear merely
changes the direction of the driven
gear. We can however use
compound gears to create
multiplicative gear ratios that can
dramatically increase torque or
RPM.
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Since the green and red gears are affixed to the same shaft, they must both have the same RPM.
We can determine the RPM of the center shaft using the ratio between the red (drive) gear and
the green (driven) gear. As noted previously the ratio is 1.6:1. Thus every time the red (drive)
gear turns 1.6 revolutions, the green (driven) gear turns 1 revolution.
We find the RPM of the green (driven) gear by dividing 100 RPM/1.6 = 62.5 RPM.
Both the red and green center gears are turning at 62.5 RPM. The red center gear now drives the
blue gear on the right.
The ratio between the red center gear and the blue gear is also 36T : 60T or 1.6:1.
We find the RPM of the blue (driven) gear by dividing 62.5 RPM/1.6 = 39.06 RPM.
The overall gear reduction is 100 RPM/39.06 RPM = 2.56:1
Note that if we MULTIPLY the two gear reductions, 1.6 x 1.6 = 2.56
Thus we can calculate the overall gear ration for gear trains with multiple gears by
MULTIPLYING the individual gear reductions.
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Try this gear problem. A 12 tooth gear drives a 48 tooth gear fixed to the center shaft. A 12T
gear is fixed to the same center shaft. The 12T gear on the center shaft drives the blue 60 tooth
gear. If the first gear in the train is rotating at 500 RPM, what is the RPM of the last gear?
48T
12T
12T
500 RPM
60T
Here is a different problem. Assume the 60T gear is the drive gear. It rotates at 500 RPM. What
would the RPM of the the final gear be?
Torque is a measure of the turning or twisting force that acts on axles, gears and shafts. Torque is
proportional to the gear ratio.
This means that in a gear drive system with a 2.66:1 ratio, the torque transmitted from the drive
gear to the driven gear is multiplied 2.66 times.
Assume that a gear of 36 teeth is driving a gear with 96 teeth. A ratio of 2.66:1 is produced.
The torque applied to the shaft of the driven gear is multiplied by 2.66.
Conversely if a gear of 96 teeth is driving a gear with 36 teeth a ratio of 1:2.66 is produced. The
torque applied to the shaft of the driven gear is divided by 2.66.
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2
1
in order to find the torque multiple created by this ratio, simply multiply the drive gear torque by
2
.
1
Looking at this mathematically we can say that a Ratio of 2.66:1 is equivilant to the fraction
1
. To find the torque
2
1
.
2
Fig. 6.3.1.14
Ratio =
Step 1.)
Step 2.)
DrivenGear 96
=
= 2.66 : 1
DriveGear 36
2.66
* 3 ft.lbs = 7.8 ft. lbs. Torqu
1
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Activities
Activity #1
Use the information in this lesson to make a careful, full sized sketch of a 8 pitch gear having 24
teeth. Use a compass, protractor, dividers, ruler and a straight edge. Accurately draw and label
the following gear geometry.
Pitch Diameter
Diametral Pitch (Pitch)
Whole Depth
Root Diameter
Pitch Circle
Number of Teeth
Pressure Angle
Circular Thickness
Addendum (Numerical
Value)
Dedendum
Circular Pitch
Activity #2
The curved section of a gear tooth is called an involute curvature. An involute can be created by
wrapping a string around a cylinder and tying a pencil on the free end. Use an 18 string, a pencil
and a tin can to create involute designs on a piece of paper. Keep the paper in your notebook.
Print your name, and the date you completed this assignment on the top of the page.
Activity #3
Download the GEARS-IDS Activity_document_6.3.1_Assemble Gear_drive.pdf. Use the
GEARS-IDS components and the instructions provided in this manual to construct a mobile
robot chassis powered by an electric motor and a gear drive. This mobile chassis can be used for
experiments associated with torque, velocity, robot control and more.
Note: This activity requires the GEARS-IDS optional Gear Set. Call 781-878-1512 to order the
optional gear set. It is possible to construct this gear drive module with standard gears that can be
obtained from a variety of sources.
Activity#4
Choose a gear drive related topic and independently prepare a 4-8 slide presentation that shares
the knowledge and information you have gained through your research. Use graphics that you
create in CAD, Photoshop, Power Point, etc. The expectation is that the presentation will be
informative and interesting for the audience.
Activity#5
Create a spreadsheet program that can solve for 5 or more of the following gear values:
Pitch Diameter
Pitch Circle Circumference
Diametral Pitch
Addendum
Base Circle
Dedendum
Whole Depth
Outside Diameter
Root Diameter
Circular Pitch
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Worksheets.
Refer to Worksheet 6.3.1.1
Manufacturing course.the grand daddy of all the robot and engineering games we hear about
today!
The matrix on the following page is offered as an example of a Rubric written to reflect the
objectives, standards and activities that are directly related to this Spur Gear lesson. Teachers are
encouraged to modify this assessment tool to reflect the focus and activities they choose to
include with this unit.
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Meets/Exceeds
Requirement
Demonstrates a working
knowledge of gear
terminology through spoken,
written and visual language
Researches information
about gear drives and
generates ideas and
questions by posing
problems
Gathers, evaluates, and
synthesizes data from a
variety of sources (e.g., print
and non-print texts, artifacts,
people) to communicate their
understanding of Gear drives
Presents clear and accurate
sketches that detail and
illustrate all the
nomenclature associated
with spur gears
Calculates the key
dimensions associated with
gear design (Fig. 6.3.1.5b)
Calculates and specify gear
ratios
Completes a working model
of a gear drive and uses it to
power a mechanism.
Creates a design(s) using
involute curves.
Creates spreadsheet
solutions for commonly used
formulas
Uses equivalent expressions
to solve gear problems
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Performance assessment.
Portfolio (An organized chronology of individual achievement. This could be a notebook
or a web page or a multimedia presentation)
Work Sheets, Labs and design challenges.
Examples of Spread Sheets to Solve Gear Related Problems
Tests and Quizzes
Gear Sketches
Work Sheet
Research Presentation
Involute
Tests or Quizzes.
Media Content.
Slide Presentations
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