1. Gear
A toothed wheel that engages another toothed mechanism in order to change the
speed or direction of transmitted motion.
Gears most important feature is that gears of unequal sizes (diameters) can be
combined to produce a mechanical advantage, so that the rotational speed and torque of the
second gear are different from that of the first.
To overcome the problem of slippage as in belt drives, gears are used which produce
positive drive with uniform angular velocity.
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2.Gear Classification
Gears or toothed wheels may be classified as follows:
1. According to the position of axes of the shafts.
The axes of the two shafts between which the motion is to be transmitted, may be
a. Parallel
b. Intersecting
c. Non-intersecting and Non-parallel
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Spur gears are used in Electric screwdriver, dancing monster, oscillating sprinkler,
windup alarm clock, washing machine and clothes dryer.
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Herringbone gears
To avoid axial thrust, two helical gears of opposite hand can be mounted side by side,
to cancel resulting thrust forces. These are called double helical or herringbone gears
The most common application is in power transmission. They utilize curved teeth for
efficient, high capacity power transmission. This offers reduced pulsation due to which they
are highly used for extrusion and polymerization. Herringbone gears are mostly used on
heavy machinery.
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Just like with spur gears, the solution to this problem is to curve the gear teeth. These spiral
teeth engage just like helical teeth: the contact starts at one end of the gear and progressively
spreads across the whole tooth.
On straight and spiral bevel gears, the shafts must be perpendicular to each other, but they
must also be in the same plane. If you were to extend the two shafts past the gears, they
would intersect
The bevel gear has many diverse applications such as locomotives, marine applications,
automobiles, printing presses, cooling towers, power plants, steel plants, railway track
inspection machines, etc.
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2. According to the peripheral velocity of the gears
The gears, according to the peripheral velocity of the gears, may be classified as:
(a) Low velocity, (b) Medium velocity, and (c) High velocity.
The gears having velocity less than 3 m/s are termed as low velocity gears and gears having
velocity between 3 and 15 m / s are known as medium velocity gears. If the velocity of gears
is more than 15 m / s, then these are called high speed gears.
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3.Nomenclature of spur gears
Pitch surface: The surface of the imaginary rolling cylinder (cone, etc.) that the toothed gear
may be considered to replace.
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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.
Root (or 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 root 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.
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: pitch diameter 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 (Pc) : The width of a tooth and a space, measured on the pitch circle.
D
Pc
N
Diametral pitch (Pd): The number of teeth of a gear unit pitch diameter. A toothed gear must
have an integral number of teeth. The circular pitch, therefore, equals the pitch circumference
divided by the number of teeth. The diametral pitch is, by definition, the number of teeth
divided by the pitch diameter. That is,
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N
Pd
D
Where
Pc = circular pitch
Pd = diametral pitch
N = number of teeth
D = pitch diameter
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.
m = D/N
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.
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.
Path of contact: The path traced by the contact point of a pair of tooth profiles.
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.
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4.Forms of Teeth
Following are the two types of teeth commonly used.
1. Cycloidal teeth and 2. Involute teeth.
1. Cycloidal Teeth
A cycloid is the curve traced by a point on the circumference of a circle which rolls without
slipping on a fixed straight line. When a circle rolls without slipping on the outside of a fixed
circle, the curve traced by a point on the circumference of a circle is known as epicycloid. On
the other hand, if a circle rolls without slipping on the inside of a fixed circle, then the curve
traced by a point on the circumference of a circle is called hypocycloid.
2. Involute Teeth
An involute of a circle is a plane curve generated by a point on a tangent, which rolls on the
circle without slipping or by a point on a taut string which is unwrapped from a reel. In
connection with toothed wheels, the circle is known as base circle.
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Literature Review
There has been a great deal of research on gear analysis, and a large body of literature
on gear modeling has been published. The gear stress analysis, the transmission errors, and
the prediction of gear dynamic loads, gear noise, and the optimal design for gear sets are
always major concerns in gear design.
Krishanu et al. (2015) analysed static stresses for spur gear with different pressure
angles. The analysed results of a symmetric type involute profiled spur gear pair at different
pressure angles are compared. Gears are one of the most important and crucial component in
a mechanical power transmission unit and also in most of the industrial rotating machineries.
Generally, a spur gear pair in action undergoes two types of stresses: the bending stress and
the contact stress. In this paper, both these stresses on the gear tooth pair are analyzed using
the finite element analysis and are compared. The stresses on the gear tooth are first analyzed
using a finite element software and then those results are validated using the conventional
formulae for finding stresses in gear tooth.
Rajaprabakaran et al. (2014) analysed high stress concentration at the root and the
point of contact. The repeated stressing on the fillets causes the fatigue failure of gear tooth.
The main objective of this study is to add different shaped holes to reduce stress
concentration. A finite element model of Spur gear with a segment of three teeth is
considered for analysis and stress concentration reducing holes of various sizes are
introduced on gear teeth at various locations. Analysis revealed that aero-fin shaped hole
introduced along the stress flow direction yielded better results.
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Prajapati et al. (2013) analyzed bending stress at critical section of asymmetric spur
gear. Bending stress at critical section is most important parameter in gear design. It must be
low as low possible. To minimize it by optimize all affected Parameters of asymmetric spur
gear tooth to reduce Bending Stress at critical section of tooth. This reduction can translate
into Increased Load Capacity, Size and Weight Reduction, Longer Life, Cost Reduction,
Increased Reliability, Noise and Vibration reduction, Increased Gear Efficiency and
Maintenance Cost Reduction etc. As the pressure angle on drive side increases, the bending
stress reduces at critical section of asymmetric spur gear. But Decision on maximum
magnitude of drive side pressure angle is constraint by the safe contact ratio and tooth
peaking effect. These way parameters are affecting directly or indirectly on performance.
There are so many parameters are likes Contact ratio, Top land tip thickness, Pressure angle
on drive side profile, Pressure angle on coast side profile, Asymmetry factor, No. of teeth,
Interference, Undercut, Centre distance, Gear ratio, Critical section thickness, Profile shift of
pinion, Profile shift of gear, Module, Bending stress at critical section, Optimal fillet radius
and Balance stress etc. affects the performance.
Rincon et al. (2013) presented the procedure to determine loaded transmission error
of a spur gear transmission as well as meshing stiffness and load sharing ratio. The procedure
also allows a better representation of load transfer between teeth pairs. The analysis of
contact forces and deformations in spur gear transmissions was done using an advanced
model. The deformation at each gear contact point was assumed as a combination of a global
and a local term. The global term was obtained by means of a finite element model and the
local term was described by an analytical approach derived from Hertzian contact theory. The
quasi static behaviour of a single stage spur gear transmission was discussed in this study
using numerical example, which showed the capabilities of the methodology to obtain the
loaded transmission error under several load levels as well as some other related measures
such as load ratio or meshing stiffness.
Ristivojevic et al. (2013) studied the impact of load distribution in meshed teeth.
Also teeth geometry and manufacturing accuracy on wear of the spur gear tooth flanks were
studied in this paper. Due to wearing causes uneven load distribution hence dynamic forces
increases, and thus energy efficiency was decreases. A larger number of impacts on the tooth
flanks stress state were taken into account so as to reach more accurate model for the analysis
of tooth flanks load carrying capacity. A mathematical model depending on the value and
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sign of base pitch difference of meshed teeth developed for the contact stress during contact
period. It was concluded that the original geometry and proper teeth mesh were impaired by
adhesive wear. This results in the lower efficiency, larger variation of load distribution and
higher dynamic forces. Uniformity and intensity of tooth flanks wear depend on pitch point
position on the profiles of meshed teeth.
Kim et al. (2010) analysed the dynamic response of a pair of spur gears having
translational motion due to bearing deformation. A new dynamic model for the gear set was
formed considering translational motion which means the distance between the centres of a
pinion and a gear varies with time. So the pressure angle and the contact ratio were
considered as time varying variables. The dynamic responses were computed by applying the
Newmark time integration method after deriving nonlinear equations of motion for gears. The
new model gave more accurate dynamic responses. The effects of damping and stiffness upon
the dynamic responses were also investigated.
Shuting et al. (2008) investigated the effect of addendum on tooth contact strength,
bending strength and other performance parameters of spur gears. Mathematical
programming method (MPM) and finite element method (FEM) were used together to
conduct loaded tooth contact analyses (LTCA), deformation and stress calculations of spur
gears with different addendums and contact ratios. Tooth load, load-sharing, contact stresses,
root bending stresses, transmission errors and mesh stiffnesses of the spur gears were
analyzed. Effects of addendum and contact ratio on gear strength and basic performance
parameters were also discussed.Finally, strength calculations of HCRG by considering
misalignment error and lead crowning were presented in this paper.
Podzharov et al. (2008) used high contact ratio spur gears to exclude or reduce the
variation of tooth stiffness. In this work the analysis of static and dynamic transmission error
of spur gears with standard tooth of 20 profile angle was presented. A simple method for
designing spur gears having a contact ratio nearly 2.0 was used. It included the increasing the
number of teeth on mating gears and simultaneously introducing negative profile shift in
order to provide the same center distance. A tooth mesh of periodic structure was used to
consider deflection and errors of each pair of teeth in the engagement. Computer programs
were developed to calculate static and dynamic transmission error of gears under load. This
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analysis of gears concluded that gears with high contact ratio have much less static and
dynamic transmission error than standard gears.
Objective of Study
Gear teeth fails due to the static and the dynamic loads acting over it, also the contact
between the two mating gears causes the surface failures. The gear fails without any warning
and the results due to this failure are catastrophic. Since the requirements are broad and are of
varying difficulty, gearing is a complex and diversified field of engineering. It includes gear
mathematics, geometrical design, strength and wear, material and metallurgy, fabrication and
inspection. Each parameter of gear plays important role in designing of gears. Following are
objectives of present study:
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Experiment Analysis
It is difficult to accurately predict the contact stress using conventional methods. On the
contrary, the contact stress and deformation can be accurately predicted using the finite
element method for contact problems with proper definition of gear geometry, loading and
boundary conditions. The spur gear is designed using ANSYS design modular. The material
used is structural steel. The various properties of gear used are:
1. Pitch Radius, = 63.5mm
2. Pressure Angle, = 20
3. No. of Teeth, = 20
4. Module, m = 6.8mm
5. Radius of Addendum, = 69.8mm
6. Radius of Dedendum, = 55.8mm
7. Shaft Radius, = 31.75mm
8. Fillet radius, r = varies between 1.27 to 3.30mm
9. Thickness, = 25.4mm
The analysis for the contact stress at the gear tooth is done by using different fillet radius
for the gear tooth. A moment of 1690 N-m is applied for the analysis. The Equivalent (von-
Mises) stress is calculated using ANSYS Workbench 17.2 and results are prepared.
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Equivalent (von-Mises) stress using different fillet radius
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Results and conclusion
The following values of stress are obtained for different fillet radius:
1 1.27 145.34
2 1.77 159.98
3 2.15 145.57
4 2.54 158.44
5 3.30 152.47
Conclusion
The effect on the strength of spur involute gear by changing the radius of the circular
fillet was investigated. Gears of different parameters but having same module and pressure
angle was modelled and the contact stress due to the loading at the highest point of single
tooth contact was analysed by using Finite Element Analysis. From the analysis it is
concluded that, as the fillet radius increases from 1.27mm to 1.77mm and from 2.15mm to
2.54mm the contact stress increases. The minimum value of stress is obtained at 1.27mm and
2.15mm so gear is more safe at these values.
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References
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14. E. Podzharov, V. Syromyatnikov, J. Navarro and R. Navarro, Static and Dynamic
Transmission Error in Spur Gears, The Open Industrial and Manufacturing Engineering
Journal, 2008, Vol. 1, page 37-41.
15. Shuting Li, Finite Element Analysis for Contact Strength and Bending Strength of a Pair
of Spur Gears With Machining Errors, Assembly Errors And Tooth Modifications,
Mechanism and Machine Theory, 2007, Vol.42, page 88114.
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