fundamentals of gears
DESCRIPTION
MEMS 1029 Gear NotesTRANSCRIPT
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MEMS1029 – Mechanical Design II Page 1
Fundamentals of Gears
MEMS1029
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FUNDAMENTALS AND
NOMENCLATURE
MEMS1029 – Mechanical Design II Page 2
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Why gears?
• Usually used as part of a transmission to convert
high-speed/low-torque to low-speed/high-torque
– Speed=voltage (cheap)
– Torque=current (expensive)
www.lego.com
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Technical Info
• AGMA
– American Gear Manufacturer’s Association
– “Fill your mind with the latest gear research!” at the annual mtg.
• Machinery’s Handbook
– Every design engineer should have a copy
• Gear design textbooks
– Just scan Amazon
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Where to get more info?
• Stock Drive Products (www.sdp-si.com)
• PIC Design (www.pic-design.com)
• WMBerg (www.wmberg.com)
• Boston Gear (www.bostongear.com)
• Lots of vendors, all with technical literature,
design guidelines, and application engineers
who live gearing.
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Customized gearing design
• Standard gears should be a first choice, but custom gears
can be made in any shape.
– See examples and technical papers at AKGears,
(www.akgears.com)
• New manufacturing techniques have allowed almost any
shape you can design to be made (but maybe at a cost…)
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Range of sizes and applications
• Little ones are on the
nanoscale (carbon
nanotubes).
• Common in MEMS
applications on the
microscale.
• Larger sizes in ships,
telescopes,
drawbridges, power
generation, …
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Conjugate Action• Mating gear teeth are
similar to cams, and said to have conjugate actionwhen designed to produce a constant angular velocity ratio when meshing.
• Involute profile almost universal for gear teeth.
• Line of action (common surface normal at point of contact) always intersects O-O at a constant pitch point P.
• Radius of each circle is called the pitch radius.
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Basic Law of Gearing
• A common normal (the line of action) to the tooth profiles at their point of contact must, in all positions of the contacting teeth, pass through a fixed point on the line-of-centers called the pitch point
• Any two curves or profiles engaging each other and satisfying the law of gearing are conjugate curves, and the relative rotation speed of the gears will be constant.
– (Slocum, Fundamentals of Design, Ch. 6)
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Generation of an Involute
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Constructing an Involute
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Gear Layout
• Pressure angle φ is usually 14.5, 20, or 25 degrees.
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Pressure Line
• Pressure line is line of contact – line forces act on.
rb=r cosφ
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Nomenclature
• Pitch circle: Theoretical circle upon which all
calculations are based.
• Pitch diameter: Diameter of pitch circle.
• Circular pitch: Distance from a point on one tooth
to a corresponding point on the adjacent tooth
measured on the pitch circle.
• Module: Ratio of pitch diameter to number of
teeth (pitch diameter in mm, metric only)
• Diametral Pitch: Ratio of number of teeth to the
pitch diameter (teeth per inch, english only)
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Nomenclature
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Basic Relationships
pP
mN
dp
N
dm
d
NP
pitchcircular
mm diameter,pitch
mm module,
in diameter,pitch
teethofnumber
inchper teeth pitch, diametral
p
d
m
d
N
P
• Governed by AGMA and ANSI standards.
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Tooth Action
• When properly
designed, gears
have points of
rolling contact
all with the
pressure line as
a constant
surface normal.
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Rack and Pinion
• Gear radius is infinite (straight-walled teeth)
• Converts rotary to linear motion, but without mechanical advantage of a screw mechanism.
pb=pc cosφ
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Internal (Ring) Gear
• Centers of rotation are on same side of the pitch point.
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Backlash
• Backlash is the amount by which the width
of a tooth space exceeds the the thickness of
the engaging tooth.
– Felt as “slop” or lost motion on direction
reversals.
– Anti-backlash gears available for special cases.
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Contact Ratio
• Contact ratio mc measures the average number of
teeth in contact. Prefer > 1.2
cosp
Lm
p
q
p
qqm
abc
trac
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Interference• The base of the gear
tooth profile is not a
perfect involute, any
contact on this
noninvolute portion of
the flank is refererred
to as interference.
• Interference can be
eliminated by
undercutting, but this
weakens the tooth
profile.
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Forming Gear Teeth
• Milling, shaping, hobbing for basic profile.
• Grinding, lapping, burnishing for finishing.
• Manufacturing and inspecting gears
generally requires specialized equipment
and techniques beyond a typical machine
shop (at least for volume production)
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Gear Shaping
• Pinion (or rack) cutter
reciprocates while
being fed into the
correct depth.
• Both cutter and gear
are rotated slightly
after each cutting
stroke and cycle
continues.
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Gear Hobbing• “Gear Hob” is a spiral
cutting tool shaped like a
worm.
• Hob and blank are rotated
at the proper angular
velocity ratio while hob is
fed across the face of the
blank.
• Requires specialized tools.
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Materials
• Gears are made from almost every
engineering material
– Steel used where tooth strength is required.
– Aluminum can be used with proper surface
treatment.
– Brass and bronze used with worm-gears for
wear-in over time.
– Plastics and reinforced composites very
common, especially in consumer applications.
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Four basic types
• Spur gears
• Helical gears
• Bevel gears
• Worm gears
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Types of Gears – Spur Gears
• Spur gears have teeth
parallel to axis of
rotation and transmit
motion between
parallel shafts.
• Remember Legos?
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Types of Gears – Helical Gears
• Helical gears have teeth inclined to the axis of rotation so teeth engage gradually
– Less noisy
– More contact area
– Can be used with non-parallel shafts
– But…generate thrust loads that must be designed for in bearing support structure.
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Helical Gears• Shape is an involute
helicoid, formed by
unwrapping a spiral.
• Gears contact gradually,
starting at a point and
extending to a line with
full engagement.
– Spur gears contact all at
once with line contact.
• Transmission is smooth
and quiet, but axial thrust
is generated.
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Double Helical Gears
• Helixes come together in a V-shape.
• Also known as herringbone gears.
• Axial thrust force is cancelled, extremely useful for heavy loads and high speeds.
• Can be made from separate gears in an assembly.
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Pitch in Helical Gears
anglehelix
pitchcircular axial
pitchcircular transverse
pitchcircular normal
tan
cos
x
t
n
tx
tn
p
p
p
pp
pp
• Angularity of the teeth complicates definitions.
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Pressure Angle in Helical Gears
anglehelix
angle pressuredirection transverse
angle pressuredirection normal
tan
tancos
t
n
t
n
• Angularity of the teeth complicates definitions.
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Types of Gears – Bevel Gears
• Bevel gears have teeth formed between conical surfaces; usually used to transmit power between intersecting shafts.
• Straight or spiral toothed.
• Called hypoid if the shafts are offset and non-intersecting.
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Straight Bevel Gears
• Used to transmit
motion between
intersecting shafts.
– Usually 90 deg, but not
always.
• Pitch measured at the
large end of the tooth
P
G
G
P
N
N
N
N
tan
tan
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Types of Gears – Worm Gears
• Worms and worm
gears strongly
resemble screws.
– Transmission ratios
can be very high.
– Can be left-handed or
right-handed threads.
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Worm Gears
• Used to generate extremely high transmission ratios.
• Customary to specify lead angle λ on the worm, and the helix angle ψG on the gear.
• Also stage axial pitchon worm and transverse circular pitch on gear.
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Tooth Systems
• Standard tooth shapes created by the
American Gear Manufacturers Association
(AGMA).
– See text for reference.
– Vendors are better source of info.
• Allow use of standardized components and
replacements (spares).
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GEAR TRAINS
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Gear Trains
• Ratio of input to output speed proportional to
number on teeth on different gear combinations.
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Calculating Transmission Ratio
• Same equations can be used with pitch diameters instead of numbers of teeth.
• Covention is e positive if last gear rotates in same direction as first gear.
FL enn
e
nN
N
N
N
N
Nn
nN
Nn
numbersth driven too ofproduct
numbers tooth driving ofproduct
2
6
5
4
3
3
26
2
3
23
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Compound Gear Trains
• Given a specified
transmission ratio,
start by determining
the number of stages,
the break into
proportions for each
stage.
• Pitch diameters follow
from number of teeth.
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Compound Gear Trains
• Arthur Ganson, “Machine with Concrete” on exhibit at MIT Museum (Cambridge, MA).
• 12 sets of 50:1 worm gear reducers.
• Driving motor (not shown) turns at 212 RPM.
• Final gear embedded in concrete block.
• How long until final gear makes one theoretical turn?
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Compound Reverted Gear Trains
• Input and output shafts are collinear, but this
forces distances between the shafts to be the same.
d2/2+d3/2=d4/2+d5/2 or N2+N3=N4+N5
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Example
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Shaft a rotates at 600 rpm. Find the speed and direction of shaft d.
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Example
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CW rpm06.4760051
4
0784.051
4
60
20
17
8
40
20
dn
e
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Planetary Gears
• Planetary gear trains always contain a sun gear, a
planet carrier (or arm), and a planet gear.
• Systems have two degrees of freedom, meaning
that they need two inputs for constrained motion.
Reuleux Collection
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FORCE ANALYSIS
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Forces along line of action
• Angled line of action leads to force trying to push gears
apart…provide means of support in your design.
www.lego.com
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Force Analysis – Spur Gearing
• Generate free body diagrams of each gear.
– Keep consistent sign convention.
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Force Analysis – Spur Gearing
power2/
torque2
load dtransmitte32
dWTH
Wd
T
FW
t
t
t
t
• Resolve forces into radial and tangential components.
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Power Calculations
• Transmitted power
depends on gear
diameter and gear
speed.
– Watch units in
calculations, especially
with English units.
• Rolling contact leads
to high efficiencies,
usually > 98%. rev/min speed,gear
mm diameter,gear
Wpower,
N load, dtransmitte
60000
UnitsSI
n
d
H
W
dn
HW
t
t
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Force Analysis – Bevel Gearing
sintan
costan
ta
tr
av
t
WW
WW
r
TW
• Convention is to assume that all forces act at the midpoint of the tooth (close enough).
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Force Analysis – Helical Gearing
coscos
tan
tan
sincos
coscos
sin
n
t
ta
ttr
na
nt
n
WW
WW
WW
WW
WW
WW
• Assumed point of force application is in the pitch plane
and in the center of the gear face.
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Force Analysis – Worm Gearing
cotcos
tancos
sincoscos
sin
cossincos
f
f
fWW
WW
fWW
n
n
n
z
n
y
n
x
• Worm gears are all sliding contact (not rolling)
– efficiency is a function of geometry and coefficient of friction
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