Unit-2 : Lecture-1

Today’s Target
 Gear and its Advantages and Disadvantages
 Classification of gears
 Basic Terminology used in Gears AKTU 2018-19
 AKTU PYQs
 MECHANICAL ENGINEERING
Theory of Machines

Unit-2 Syllabus
Cams: Introduction, classification of cams and followers, cam profiles for knife
edge, roller and flat faced followers for uniform velocity, uniform acceleration
Gears and gear trains: Introduction, classification of gears, law of gearing,
tooth forms and their comparisons, systems of gear teeth, length of path of
contact, contact ratio, minimum number of teeth on gear and pinion to avoid
interference, simple, compound, reverted and planetary gear trains, sun and
planet gear train.
 Point of contact (Q)
GEAR

Gear is a mechanical component which is used to R1 R2

𝜔1 𝜔2
 transmit power
 increase/decrease speed,
 change direction

Point of contact (Q)

Lies also on body 1 Lies also on body 2
v1​=R1𝜔1 v2​=R2 𝜔2
R1 𝜔 1 = R2 𝜔2 ⟹ condition for no slipping ⟹ No power loss

𝜔1 R2
= ​=​ const.
𝜔2 R1
 In condition of slip
ω1
Power loss takes place and ≠ const.
ω2
Those drives in which slip is possible is negative drive.

Examples:- Belt drive, rope drive, chain drives.

90% of drive used is this type of drive.

In some system (only 10%), very high level of accuracy is demanded for the
velocity ratio to be constant.
ω1 R2
= ​= const.
ω2 R1
⟹ Slip is impossible ⟹ Positive drive ⟹ Gear drive

Manufacturing cost
> 100
Material cost
 Advantages and Disadvantages of Gear Drive
 The following are the advantages and disadvantages of the gear drive as
compared to belt, rope and chain drives:
Advantages of Gear Drive
 It transmits exact velocity ratio.
 It may be used to transmit large power.
 It has high efficiency.
 It has reliable service.
 It has compact layout.
Disadvantages of Gear Drive
 The manufacture of gears requires special tools and equipment.
 The error in cutting teeth may cause vibrations and noise during operation.
 Classification of gears
(A) Classification on the basis of axes of shaft connected
(i) Both axes are parallel
In this case pure rolling motion can be transmitted between two cylinder surfaces in contact.
(a) Spur gear: Teeth are straight (top land) and parallel to axis of rotation.
 99% failed, only 1% use in very low transmission of power at very low speed.
 Instantaneous engagement and disengagement takes place so impact stresses is developed.
 (b) Helical gear: Teeth are straight but inclined to the axis of rotation.
 Gradual engagement takes place because opposite hand helical gears must be in contact.
 Due to this impact stress is eliminated.

 Since here F can't be cancelled so axial force is developed. Left-hand helical gear

 To eliminate axial thrust of helical gear ⟶ Double helical

gear is used.
 Double helical gear is also called herringbone gear.

Right-hand helical gear

Double helical gear

 (ii) Axes are non-parallel but intersecting
Bevel gear: Pure rolling motion can be transmitted between two conical surfaces in
contact.

Bevel gear
Straight Bevel gear Helical Bevel gear
 Impact stress is there in Straight Bevel gear .
 Teeth are straight and parallel to the axis of rotation.
 1% use.
 Therefore Helical Bevel gears are used
 Mitre Gears are a special type of bevel gears that are used
to transmit motion at exactly 90° between two shafts, and
both gears have the same number of teeth.
 (III) Axes are neither parallel nor intersecting
 The two non-intersecting and non-parallel i.e. non-coplanar shaft connected by gears.
 This type of gearing also have a line contact, the rotation of which about the axes
generates the two pitch surfaces known as hyperboloids.
 Pure rolling is impossible.
 Rolling is possible and it is having rotational + partial sliding motion.

Spiral gear: It is also called skew-bevel gear.

Example of spiral gear: worm and worm wheel
Worm and worm wheel gear is used or famous
for high speed reduction ratio. 10:1, 30:1, 100:1,
1000:1, 1250:1.
 (B) Classification of gears on the basis of type of gearing
(i) External gearing
The direction of rotation of both the gears is opposite.
Bigger:- Gear
Smaller:- Pinion

(ii) Internal gearing

Bigger:- Annular (ring)
Smaller:- Pinion.
 Bigger have internal teeth while smaller has
external teeth.
 Both rotate in same direction.
 (C) Classification 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 (If velocity is less than 3 m/s )
(b) Medium velocity (having velocity between 3 and 15 m/s )
(c) High velocity (If the velocity of gears is more than 15 m/s)
Note
 If more than one gears are mounted on same shaft called compound gears and
speed of all are same.
 In general in power transmission, smaller bodies are made as drivers because
less torque is required at input due to more speed (P=Tω).
 AKTU PYQ
Define the terms pitch circle diameter, pressure angle, addendum, dedendum, circular pitch,
module and backlash related to gear. AKTU 2018-19
Basic Terminology used in Gears AKTU 2018-19
 Basic Terminology used in Gears AKTU 2018-19
Pitch circle
"It is an imaginary circle in the gears where pure rolling motion is observed when mating
gears are transmitting powers". Being an imaginary circle, it can't be the physical
characteristics of the gear but being the most imp. circle it is one of the biggest
specification of the gear.
2. Pitch circle diameter.
It is the diameter of the pitch circle. The size of the gear is usually specified by the pitch circle
diameter. It is also known as pitch diameter.
3. Pitch point.
It is a common point of contact between two pitch circles.
4. Pitch surface.
It is the surface of the rolling discs which the meshing gears have replaced at the pitch circle.
5. Pressure angle or angle of obliquity (ϕ).
Angle between line of action and common tangent at P.
It is usually denoted by φ.
The standard pressure angles are 14½° and 20°.
6. Addendum.
It is the radial distance of a tooth from the pitch circle to the top of the tooth.
7. Dedendum.
It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
8. Addendum circle.
It is the circle drawn through the top of the teeth and is concentric with the pitch circle.
9. Dedendum circle.
It is the circle drawn through the bottom of the teeth. It is also called root circle.
 10. Circular pitch
It is the distance measured on the circumference of the pitch circle from a point of one
tooth to the corresponding point on the next tooth. It is usually denoted by pc.

𝜋𝐷
𝑝𝑐 = 𝑤ℎ𝑒𝑟𝑒 𝐷 = 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑝𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 , 𝑇 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ
𝑇

If D₁ and D₂ are the diameters of the two meshing gears having the teeth T₁ and T₂ respectively,
then for them to mesh correctly,

11. Diametral pitch

It is the ratio of number of teeth to the pitch circle diameter in millimetres. It is denoted by Pd.
Mathematically,
 12. Module.
 It is the ratio of the pitch circle diameter in millimeters to the number of teeth.
It is usually denoted by m.
Mathematically,

13. Clearance
 It is the radial distance from the top of the tooth to the bottom of the tooth, in a meshing gear.
 A circle passing through the top of the meshing gear is known as clearance circle.
14. Total depth.
 It is the radial distance between the addendum and the dedendum circles of a gear.
 It is equal to the sum of the addendum and dedendum.

15. Backlash
 Backlash is the small gap or clearance between the mating teeth of two gears.
 Backlash prevent the jamming between the teeth due to thermal expansion.
 Unit-2 : Lecture-5
Today’s Target
➢ Gear train and its types
➢ Simple gear train
➢ Compound gear train
➢ AKTU PYQs
 Gear Train
Sometimes, for high velocity ratio, combination of gears is to transmit power from one shaft to
another. Such a combination of gears is called a gear train.

Types of Gear Trains

1. Simple gear train
2. Compound gear train
3. Reverted gear train
4. Epicyclic gear train
 1. Simple Gear Train
➢ When there is only one gear on each shaft, as shown in Fig. it is called as simple gear train.
➢ Since the gear 1 drives the gear 2, therefore gear 1 is called the driver and the gear 2 is
called the driven or follower.

Let
N1 = Speed of gear 1(or driver) in r.p.m.
N2 = Speed of gear 2 (or driven or follower) in r.p.m.
T1 = Number of teeth on gear 1
T2 = Number of teeth on gear 2

𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑟 𝑁1 𝜔1 𝑇2
Speed ratio (or velocity ratio)= = = =
𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑁2 𝜔2 𝑇1

𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑛 𝑁2 𝜔2 𝑇1
Train value of the gear train= = = =
𝑠𝑝𝑒𝑒𝑑 𝑜𝑓 𝑑𝑟𝑖𝑣𝑒𝑟 𝑁1 𝜔1 𝑇2

➢ train value is the reciprocal of speed ratio.

 ➢ Sometimes, the distance between the two gears is large.
➢ In such a case the motion from one gear to another, may be transmitted by the following two
methods:
1. By providing the large sized gear
2. By providing one or more intermediate gears.
➢ First method (i.e, providing large sized gears) is very inconvenient and uneconomical method.
➢ whereas second method (i.e. providing one or more intermediate gear) is very convenient and economical.

➢ If the number of intermediate gears are odd, the direction of the driver and driven gears is same.
➢ But if the number of intermediate gears are even, the direction of the driver and driven gears is opposite.
 As driving gear 1 is in mesh with the intermediate gear 2
𝑁1 𝑇2
= ------------ (i)
𝑁2 𝑇1

as the intermediate gear 2 is in mesh with the driven gear 3

𝑁2 𝑇3
= ------------ (ii)
𝑁3 𝑇2

By multiplying the equations (i) and (ii).

➢ Speed ratio and the train value, in a

∴
𝑁1
×
𝑁2
=
𝑇2
×
𝑇3
or
𝑁1
=
𝑇3 simple gear train, is independent of
𝑁2 𝑁3 𝑇1 𝑇2 𝑁3 𝑇1
the size and number of
Speed of driver No. of teeth on driven intermediate gears.
Speed ratio = =
Speed of driven No. of teeth on driver
➢ These intermediate gears are
Speed of driven No. of teeth on driver called idle gears, as they do not
Train value = =
Speed of driver No. of teeth on driven
effect the speed ratio or train value
of the system.
➢ The idle gears are used for the following two purposes:
1. To connect gears where a large centre distance is required
2. To obtain the desired direction of motion of the driven gear (ie, clockwise or
anticlockwise).
 Compound Gear Train
➢ When there are more than one gear on a shaft, as shown in Fig., it is called a compound gear train.
➢ The distance between the driver and the driven has to be bridged over by intermediate gears and
at the same time, a speed ratio is required; then in this case, a compound gear train is used.

𝑁1 𝑇2 𝑁3 𝑇4 𝑁5 𝑇6
= ……(i) = ………(ii) = ………(iii)
𝑁2 𝑇1 𝑁4 𝑇3 𝑁6 𝑇5

by multiplying the equations (i), (ii) and (iii),

𝑁1 𝑁3 𝑁5 𝑇2 𝑇4 𝑇6
× × = × ×
𝑁2 𝑁4 𝑁6 𝑇1 𝑇3 𝑇5

𝑁1 𝑇2 ×𝑇4 ×𝑇6
or =
𝑁6 𝑇1 ×𝑇3 ×𝑇5

Speed of the first driver Product of the number of teeth on the drivens
Speed ratio = =
Speed of the last driven or follower Product of the number of teeth on the drivers
Note: The two gears that mesh must have the same circular pitch or module.
 Question: The gearing of a machine tool is shown in Fig. The motor shaft is connected
to gear A and rotates at 975 r.p.m. The gear wheels B, C, D and E are fixed to parallel
shafts rotating together. The final gear F is fixed on the output shaft. What is the speed
of gear F? The number of teeth on each gear are as given below:
Gear A B C D E F
No. of teeth 20 50 25 75 26 65
Solution.
Given: 𝑁𝐴 = 975 𝑟. 𝑝. 𝑚. ; 𝑇𝐴 = 20; 𝑇𝐵 = 50 ; 𝑇𝐶 = 25;
𝑇𝐷 = 75; 𝑇𝐸 = 26 ; 𝑇𝐹 = 65
𝑁𝐹 = ?

Speed of the first driver Product of the no. of teeth on drivens

We know that =
Speed of the last driven Product of the no. of teeth on drivers

𝑁𝐴 𝑇𝐵 ×𝑇𝐷 ×𝑇𝐹 50 ×75 ×65 𝑁𝐴 975

= = = 18.75 or 𝑁𝐹 = = , 𝑁𝐹 = 52 𝑟. 𝑝. 𝑚. 𝐴𝑛𝑠.
𝑁𝐹 𝑇𝐴 ×𝑇𝐶 ×𝑇𝐸 20 ×25 ×26 18.75 18.75
 Unit-2 : Lecture-6
Today’s Target
➢ Reverted Gear Train
➢ Numerical Problem
➢ AKTU PYQs
 2. Compound gear train

1. Simple gear train

4. Epicyclic gear train

3. Reverted gear train

 Reverted Gear Train

➢ When the axes of the first gear (i.e. first driver) and the
last gear (i.e. last driven or follower) are co-axial, then the
gear train is known as reverted gear train as shown in Fig.
➢ In a reverted gear train, the direction of the first gear and
the last gear is same.

𝑟1 + 𝑟2 = 𝑟3 + 𝑟4

If the module of all the gears is assumed to be the same,

∴ 𝑇1 + 𝑇2 = 𝑇3 + 𝑇4
 Product of number of teeth on drivens
Speed ratio =
Product ofnumber of teeth on drivers
𝑁1 𝑇2 ×𝑇4
or =
𝑁4 𝑇1 ×𝑇3

The reverted gear trains are used in automotive transmissions, lathe back gears, industrial
speed reducers, and in clocks (where the minute and hour hand shafts are co-axial).
 Question: The speed ratio of the reverted gear train, as shown in Fig. is to be 12. The
module pitch of gears A and B is 3.125 mm and of gears C and D is 2.5 mm. Calculate
the suitable numbers of teeth for the gears. No gear is to have less than 24 teeth.
[AKTU 2022-23]

Solution. 𝑮𝒊𝒗𝒆𝒏: 𝑺𝒑𝒆𝒆𝒅 𝒓𝒂𝒕𝒊𝒐,

𝑵𝑨
,
𝑵𝑫
mA​ = mB​ = 3.125 mm; mC​ = mD​ =2.5mm

Since the speed ratio between the gears A and B and between the
gears C and D are to be the same, therefore:

𝑵𝑨 𝑵𝑨 𝑵𝑪 𝑵𝑨 𝑵𝑪
= × = 𝟏𝟐 = = 𝟏𝟐 = 𝟑. 𝟒𝟔𝟒
𝑵𝑫 𝑵𝑩 𝑵𝑫 𝑵𝑩 𝑵𝑫
the speed ratio of any pair of gears in mesh is the inverse of their number of teeth. Therefore:
𝑻𝑩 𝑻𝑫
= = 𝟑. 𝟒𝟔𝟒 𝑇𝐵 = 3.464 𝑇𝐴 … … . (𝑖 ) 𝑇𝐷 = 3.464 𝑇𝐶 ……….(ii)
𝑻𝑨 𝑻𝑪
𝐹𝑟𝑜𝑚 𝑒𝑢𝑎𝑡𝑖𝑜𝑛 𝑖 𝑎𝑛𝑑 𝑖𝑖𝑖 𝑇𝐴 = 28 𝑎𝑛𝑑 𝑇𝐵 = 100

𝐹𝑟𝑜𝑚 𝑒𝑢𝑎𝑡𝑖𝑜𝑛 𝑖𝑖 𝑎𝑛𝑑 𝑖𝑣 𝑇𝐶 = 36 𝑎𝑛𝑑 𝑇𝐷 = 124