Gear manufacturing process developments by Engr Rehan Zeb Khan PMAS AAUR

1. Gears Manufacturing
by,
Engr Rehan Zeb Khan
Arid Agriculture University Rawalpindi

2. Gears Manufacturing
Gear Basics

3. GEAR…..
 A gear is a component within a device that
transmits rotational force to another gear
or device.
 In machinery, the general term “shaft”
refers to a member, usually of circular
cross-section, which supports gears,
sprockets, wheels, rotors, etc., and which is
subjected to torsion and to transverse or
axial loads acting singly or in combination.

4. Gears Purpose
 Transmit rotating motion
 Normally mounted on shaft
 Transmits rotating motion from one
parallel shaft to another

5. Interaction
 Gears and Shafts can interact three
ways
→ Shaft can drive the gear
→ Gear can drive the shaft
→ Gear can freewheel on shaft

6. SPUR GEAR
 Teeth is parallel to
axis of rotation
 Transmit power from
one shaft to another
parallel shaft
 Used in Electric
screwdriver,
oscillating sprinkler,
windup alarm clock,
washing machine and
clothes dryer

7. External and Internal spur Gear…

8. Helical Gear
 The teeth on helical gears are cut at an
angle to the face of the gear
 This gradual engagement makes helical
gears operate much more smoothly and
quietly than spur gears
 One interesting thing about helical gears is
that if the angles of the gear teeth are
correct, they can be mounted on
perpendicular shafts, adjusting the
rotation angle by 90 degrees

9. Helical Gear…

10. Herringbone gears
 To avoid axial thrust, two
helical gears of opposite
hand can be mounted side
by side, to cancel resulting
thrust forces
 Herringbone gears are
mostly used on heavy
machinery.

11. Rack and pinion
 Rack and pinion gears
are used to convert
rotation (From the
pinion) into linear
motion (of the rack)
 A perfect example of
this is the steering
system on many cars

12. Bevel gears
 Bevel gears are useful when the direction of a
shaft's rotation needs to be changed
 They are usually mounted on shafts that are 90
degrees apart, but can be designed to work at
other angles as well
 The teeth on bevel gears can be straight, spiral or
hypoid
 locomotives, marine applications, automobiles,
printing presses, cooling towers, power plants,
steel plants, railway track inspection machines,
etc.

13. Straight and Spiral Bevel Gears

14. Hypoid Gears
A hypoid gear is a style of spiral bevel gear whose main
variance is that the mating gears' axes do not intersect.

15. WORM AND WORM GEAR
 Worm gears are used when large gear reductions
are needed. It is common for worm gears to have
reductions of 20:1, and even up to 300:1 or
greater
 Many worm gears have an interesting property
that no other gear set has: the worm can easily
turn the gear, but the gear cannot turn the worm
 Worm gears are used widely in material
handling and transportation machinery, machine
tools, automobiles etc

16. WORM AND WORM GEAR

17. Gear Design
 Gears must have
same pitch to operate
together
 Gear Pitch
→ The number of teeth
per given unit of pitch
diameter
→ To determine pitch:
divide number of teeth
by the pitch diameter
of the gear

18. Tooth Design

19. Gear Terminology

20. Basic Gear Design
Commercially available gears are specified on drawings and are used whenever possible. Stock
gears are available in a wide range of forms and sizes. Gear design includes the selection of the
gear sizes, pitch diameter, center to center distance, size and form of the teeth, shaft diameter,
horsepower rating, speed rations, and appropriate heat treatment and materials.
In actual practice, the designer provides the detail drafter with only a few basic dimensions of the
required gears. The designer may obtain this data from actual engineering calculations or from
manufacturer's catalogs. All other dimensions needed in the construction of the working drawings are
usually worked out by the detail drafter.

21. Basic Gear Design
CENTER TO CENTER DISTANCES OF TWO FRICTION WHEELS

22. Basic Gear Design
CENTER TO CENTER DISTANCES OF TWO GEARS

23. Basic Gear Design
Diametral Pitch (P)
The diametral pitch (P) is a ratio equal to the number of teeth (N) on the gear per inch of pitch diameter (D).
Diametral Pitch (P) = Number of Teeth (N)/ Pitch Diameter (D)
Number of teeth (N)
The number of teeth (N) is the number of gear teeth on the gear or pinion.
Number of teeth (N) = Diametral Pitch (P) x Pitch Diameter (D)
Pitch Diameter (D)
The pitch diameter (D) is an imaginary circle that corresponds to the circumference of the friction gear from which the
spur gear is derived.
Pitch Diameter (D) = Number of teeth (N)/ Pitch Diameter (P)
Center to Center Distance (C to C)
The center to center distance (C to C) is the distance between the centers of the two friction wheels
C to C = (Pitch Diameter of Gear (D1) + Pitch Diameter of Pinion (D2))/2
C to C = ((D1) + (D2))/2

24. Basic Gear Design
Gear Ratio (M)
When two friction wheels of different diameter are placed together a point of the driver gear will travel the same
distance as a point of the driven gear. Therefore, the number of teeth and the speed of the gears are directly
proportional to its pitch diameter.
M1 = D1 = N1 = RPM2
M2 D2 N2 RPM1
Linear Velocity (V)
Linear velocity is the distance that a given point on the friction wheel travels during a certain time period.
Linear Velocity (V) = (pi) x Pitch Diameter of Gear (D) x RPM

25. NOMENCLATURE OF SPUR
GEARS

26. NOMENCLATURE….
 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.
 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.

27. NOMENCLATURE….
 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.
N
D
Pc
π

28. NOMENCLATURE….
 Diametral pitch (Pd): The number of teeth of a gear unit
pitch diameter. The diametral pitch is, by definition, the
number of teeth divided by the pitch diameter. That is,
Where
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
D
N
Pd =

29. VELOCITY RATIO OF GEAR
DRIVE
d = Diameter of the wheel
N =Speed of the wheel
ω = Angular speed
velocity ratio (n) =
2
1
1
2
1
2
d
d
N
N
==
ω
ω