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Introduction to Gears First Edition

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Introduction to Gears First Edition Preface The history of gears is probably as old as civilization itself. And yet today, the importance of gears in manufacturing industry is undwindling and even more growing. The purpose of this handbook is to provide an outline of gear fundamentals for those who want to acquire knowledge about mechanics of gears. In reading through this handbook, if you have any questions please refer them to us and we would be happy to respond. We hope this can start you down the road with a good sence of direction. Contents Part 1 About Gears 1. Types of Gears...........................................................................................................4 2. Characteristics of Each Type of Gears.......................................................................7 3. Gear Terminology.....................................................................................................11 4. Involute Tooth Profile...............................................................................................14 5. Pressure Angle..........................................................................................................16 6. Profile Shifted Gears................................................................................................17 7. Gear Accuracy - Testing and Inspecting..................................................................19 8. Metallic Materials for Gears and Heat Treatment...................................................21 9. Gear Noise...............................................................................................................24 10. Q & A ......................................................................................................................26 Part 2 Production Processes 27 1. Spur Gears................................................................................................................28 2. Racks........................................................................................................................30 3. Bevel Gears..............................................................................................................32 4. Production Facilities.................................................................................................34 Part 1 About Gears 1. Types of Gears 2. Characteristics of Each Type of Gears 3. Gear Terminology 4. Involute Tooth Profile 5. Pressure Angle 6. Profile Shifted Gears 7. Gear Accuracy - Testing and Inspecting 8. Metallic Materials and Heat Treatment 9. Gear Noise 10. Q & A (1) About Gears Spur Gear Helical ( 1 ) - 1 Types of Gears Shape of bevel gear ..... Spur Gear Helical Gear Rack Bevel Gear Spiral Bevel Gear Screw Gear Miter Gear Worm & Worm Wheel Internal Gear - 4 - Worm Internal Gear Worm Wheel Gear Coupling Miter Gear Involute Spline Shafts Screw Gear & Bushings Helical Gear Pawl Rack Pinion Spur Gear - 5 - Rachet Involute Spline Shafts & Bushings Spiral Bevel Gear Straight Bevel Gear (1) AboutGears (1) About Gears There are three categories of gears in accordance with the orientation of axes. 1) Parallel Axes MSGA(B),SSG(S),SS,SSA,SSY,SSAY, LS,SUS,SUSA,SUSL,DSL,NSU,PU, Spur Gear PS,PSA,DS,BSS,SSCPG(S),SSCP, SUSCP,SSR,KTSCP Helical Gear KHG,SH KRG(F),KRGD,SRGF,KRF,SR(F), SRFD,SUR(F),SURFD,BSR,DR, Rack PR(F),SRO,SROS,SURO,KRHG(F), SRH,KRG(F)(D),SRCP(F)(D),KRCPF, SURCPF(D),SRCP,FRCP Internal Gear SI,SIR Intersecting Axes 2) MMSG,SMSG,MMSA(B), Miter Gear MMS,SMS,SMA(B)(C),MM,LM, SM,SAM,SUM,PM,DM Straight Bevel Gear SB,CB,SBY,SUB,PB,DB Spiral Bevel Gear MBSG,SBSG,MBSA(B),SBS,KSP 3) Nonparallel, Nonintersecting Screw Gear AN,SN,PN,SUN Axes Worm KWGDL(S),KWG,SWG,SW,SUW Worm Wheel AGDL,AGF,AG,PG,CG,BG 4) Others Involute Spline Shaft SV,SVI & Bushing Gear Coupling GC,GC-I Pawl & Rachet SRT,SRT-C - 6 - (1) About Gears ( 1 ) - 2 Characteristics of Each Type of Gears Spur Gear Teeth are straight and parallel to shaft axis. Transmits power and motion between rotating two parallel shafts. Features ( 1 ) Easy to manufacture. ( 2 ) There will be no axial force. ( 3 ) Relatively easy to produce high quality gears. ( 4 ) The commonest type. Applications Transmission components Helical Gear Teeth are twisted oblique to the gear axis. Left Helix angle Left The hand of helix is designated as either left or right. Right Right Right hand and left hand helical gears mate as a set. But they have the same helix angle. Features ( 1 ) Has higher strength compared with spur gear. ( 2 ) Effective in reducing noise and vibration compared with spur gear. ( 3 ) Gears in mesh produce thrust forces in the axial directions. Applications Transmission components, automobile, speed reducers etc. - 7 - (1) About Gears Rack The rack is a bar containing teeth on one face for meshing with a gear. The basic rack form is the profile of the gear of infinite diameter. Racks with machined ends can be joined together to make any desired length. Features ( 1 ) Changes a rotary motion into a rectilinear motion. Applications A transfer system for machine tools, printing press, robots, etc. Internal Gear An annular gear having teeth on the inner surface of its rim. The internal gear always meshes with the external gear. Features ( 1 ) In the meshing of two external gears, rotation goes in the opposite direction. In the meshing of an internai gear with an external gear the rotation goes in the same direction. ( 2 ) Care should be taken to the number of teeth when meshing a large (internal) gear with a small (external) gear, since three types of interference can occur. ( 3 ) Usually internal gear is driven by external (small) gear. ( 4 ) Allows compact design of the machine. Applications Planetary gear drive of high reduction ratios, clutches etc. - 8 - (1) About Gears Bevel Gear One of a pair of gears used to connect two shafts whose axes intersect, and Apex the pitch surfaces are cones. Pitch cone Teeth are cut along the pitch cone. Depending on tooth trace bevel gear is classified: 1) Straight bevel gear 2) Spiral bevel gear 1 ) Straight Bevel Gear A simple form of bevel gear having straight teeth which, if extended inward, would come together at the intersetion of the shaft axes. Features ( 1 ) Relatively easy to manufacture. ( 2 ) Provides reduction ratio up to approx. 1:5. Applications Machine tools, printing press, etc. Especially suitable for a differential gear unit. 2 ) Spiral Bevel Gear Bevel gear with curved, oblique teeth to provide gradual engagement and bring more teeth together at a given time than an equivalent straight bevel gear. Features ( 1 ) Has higher contact ratio, higher strength and durability than an equivalent straight bevel gear. ( 2 ) Allows a higher reduction ratio. ( 3 ) Has better efficiency of transmission with reduced gear noise. ( 4 ) Involves some technical difficulties in manufacturing. Applications Automobile, tractor, vehicles, final reduction gearing for ships. Miter Gears A special class of bevel gear where the shafts intersect at 90° and the gear ratio is 1:1. - 9 - (1) About Gears Screw Gear A helical gear that transmit power from one shaft to another, non-parallel, non-intersecting shafts. Features ( 1 ) Used in a speed reducer and/or a multiplying gear. ( 2 ) Tends to wear as the gear come in sliding contact. ( 3 ) Not suitable for transmission of high horsepower. Applications Driving gear for automobile. Automatic machines that require intricate movement. Worm Gear Pair Worm Worm is a shank having at least one complete tooth (thread) around the pitch surface; the driver of a worm wheel. Worm wheel is a gear with teeth cut on an angle to be driven by a worm. Center distance Worm Wheel Features ( 1 ) Provides large reduction ratios for a given center distance. ( 2 ) Quiet and smooth action. ( 3 ) A worm wheel is not feasible to drive a worm except for special occasions. Applications Speed reducers, anti-reversing gear device making the most of its self-locking features, machine tools, indexing device, chain block, portable generator, etc. - 10 - (1) About Gears ( 1 ) - 3 Gear Terminology Facewidth T i α Pressure angle Reference circlep c ir c le B a R s o e o c t ir c c ir l c e T le ip Reference pitch d ia m e R te ef r er en ce d ia B m as et e er dia me ter R oot diam eter Center line t c a t n Pitch point o c f o h t a p f o h t Backlash g n e L Interference point Tooth thickness Dedendum Center distance Tooth depth Addendum - 11 - (1) About Gears Reference diameter. The Module Let me see ... of a Gear The number of teeth 1 2 3 "Module" is the unit of size to indicate how big or small a gear is. It is the ratio of the reference diameter of the gear divided by the number of teeth. Reference diameter Thus: (Module =──────────── ) Number of teeth The mutual relation between the module and the reference diameter etc. is as follows: Reference diameter ( Reference diameter = Module × Number of teeth ) Reference diameter Number of teeth ( Number of teeth = ──────────── ) Module Reference pitch ( Reference pitch = π × Module ) Then, what is the reference pitch? It is equal to the circumference divided by Circumference the number of teeth. Circumference (pd) Reference pitch Reference pitch = ───────── Number of teeth (z) Diameter Then, what is the reference circle? This is a friction pully. As the surfaces are smooth, the rotation will not go properly when great force is applied. This problem will be solved if there are teeth on the periphery of the friction pully. And this is the concept of gearing. Friction pully (Reference circle) Both reference circles
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