Gear Geometry

Kinematic model of a gear set

dp

dg

Pressure Line
Terminology
Diametral pitch (or just pitch) P : determines the size of the tooth. All
standard meshing gears have the same pitch.
P

N
d

d
N

d
N

P is pitch, p is circular pitch and m is the module.

I) Regular Gear Trains

n1
N
2
n2
N1

N1 and N2 are the number of teeth in each gear, and n1 and n2 are the gear
speed in rpm or similar units.

Internal gears
n1 N 2

n2 N1

II) Epicyclic (Planetary) Gear Trains

ARM

Epicyclic gear trains have two degrees of freedom They require two
inputs. Epicyclic gear trains can always be solved by the following two
relationships.
Relative angular velocity formula:
n 2 n A n2 / A

n1 n A n1 / A

Regular gear train formula with Arm stationary

n2 / A
N
1
n1 / A
N2

Problem #M5: Gear kinematics: The figure shows an epicyclic gear train.
The number of teeth on each gear is as follows:
N2=20
N5=16
N4=30
The input is Gear 2 and its speed is 250 rpm clockwise (positive). Gear 6 is
fixed. Determine the speed of the arm and the speed of Gear 4. The
drawing is not to scale. (Answers: -114.3 and -357.1 rpm)

Kinematics of Automobile Differential

Considering the Right Wheel, Left Wheel, the Ring Gear and the Drive Shaft
as shown in the figure,
n RW n LW 2n RG

Gear Force Analysis

Fn

Ft

d
Fr

Fn : Normal force
Ft : Torque-producing tangential force
Fr : Radial force.
33000(hp)
V
Fr Ft tan
Ft

and V

nd
12

Where n is in rpm and d is in inches:

Problem # M6 : A pair of spur gears are in mesh with a pitch of 6 are in
mesh. The pinion has 18 teeth and rotates at 1800 rpm transmitting 0.5
Hp. Both gears have 20-degree pressure angles. The number of teeth
on the gear is 36. Determine the radial and tangential forces on the
pinion. Answer (4.2 lbs and 11.7 lbs)

Helical gears
Geometric parameters
Pn : Normal pitch
P : PR pitch
: Helix angle
n: Normal pressure angle
: PR pressure angle
N : Number of teeth
d: pitch diameter
pn and p : circular pitches
pa : axial pitch
Geometric relationships:
P

N
d

tan( )

and

P Pn cos( )

tan(n )
cos( )

Pp Pn pn

and

pa

p
tan( )

Helical gear forces

Ft From Power
Fr Ft tan( )
Fa Ft tan( )

Problem # M7: A pair of helical gears transmit 15 KW power and the

pinion is rotating at 1000 rpm. The helix angle is 0.50 radians and the
normal pressure angle is 0.35 radians. The pitch diameter of the pinion
is 70 mm and the pitch diameter of the gear is 210 mm. Determine the
tangential, radial, and axial forces between the gear teeth. (Answers:
4092, 1702, 2236 Newtons)

Straight Bevel gears

Pinion

Geometric Parameters
(Pinion)

d
davg

dp: pitch diameter

davg,p: average diameter
b: Face width
pPitch cone angle

b
Bevel gear forces
Ft

33000( hp )
Vavg

where Vavg

nd avg
12

and

d avg d b sin( )
Fr Ft tan( ) tan( )
Fa Ft tan( ) sin( )

These forces are for pinion and act through the tooth midpoint. Forces
acting on the gear are the same but act on different directions.

Problem #M8:
A pair of straight-tooth bevel gears (as shown in the figure above) are in mesh
transmitting 35 hp at 1000 rpm (pinion speed). The gear rotates at 400 rpm. The gear
system has a pitch of 6 and a 20-degree pressure angle. The face width is 2 inches and
the pinion has 36 teeth. Determine the tangential, radial, and axial forces acting on the
pinion. Answers (839 lbs, 283 lbs, 113 lbs).

Worm Gear Kinematics

dw

dg

The velocity ratio of a worm gear set is determined by the number of teeth in
gear and worm thread (not the ratio of the pitch diameters).

N
N

w
g

Nw = Number of threads (single thread =1, double thread =2, etc)

The worms lead is
L pa NW

The worms axial pitch pa is the same as the gears PR circular pitch p.
The worms lead angle is the same as the gears helix angle
Example: For a speed reduction of 30 fold and a double threaded worm,
what should be the number of teeth on a matching worm gear.
Ng = (2) (30) = 60 teeth
The geometric relation for finding worm lead angle
tan( )

L
d w

Problem #M9: A worm gear reducer is driven by a 1200 rpm motor.

The worm has

3 threads and the gear has 45 teeth. The circular pitch of the gear is p=0.5, the center
distance is 4.5 inches, the normal pressure angle is 20 degrees, and face-width of the gear
is b=1 inch. Use a coefficient of sliding friction of 0.029. Determine:
a) Gear and worm diameters, and worm Lead. (7.16, 1.84, 1.5 in)
b) The worm gear efficiency (88.6%)
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c) Is the unit self-locking show work? (No)

Worm Gear Forces

The forces in a worm gear set when the worm is driving is
Fgr = Fwr

Fgt = Fwa

Fwt

Fga = Fwt

Fwa
Fwr

Usually the Fwt is obtained from the motor hp and rpm as before. The other
forces are:
Fwa

cos(n ) cos( ) f sin( )

Fwt
cos(n ) sin( ) f cos( )

The worm and gear radial forces are:

Fwr

sin(n )
Fwt
cos(n ) sin( ) f cos( )

The worm gear set efficiency is:

e

cos(n ) f tan( )
cos(n ) f cot( )

Where f is the coefficient of friction. Condition for self-locking when worm

is the driver
f cos( n ) tan( )

Bearing Reaction Forces

Bearing

Any gear or pulley

Fr
Fa

Ft

Total thrust load on bearings is Fa

For radial forces combine the radial and tangential forces into F:
F

Fr2 Ft 2

Flat Belts
Flat belts have two configurations:
Open

Dd
)
2C
Dd
2 sin 1 (
)
2C

d 2 sin 1 (
D

Closed (Crossed)

d D 2 sin 1 (

Dd
)
2C

Where
C: Center-to-center distance
D,d: Diameters of larger and smaller rims
Slippage Relationship

F1
e
F2

10

Tight side
Driver

is in radians.

F1
F2

Slack side

Transmitted Hp is
Hp

( F1 F2 )V
33000

Where F1 and F2 are in lbs and V is in ft/min.

Initial Tension
Belts are tensioned to a specified value of Fi. When the belt is not
transmitting torque:
F1=F2=Fi
As the belt start transmitting power,
F1 = Fi + F and F2 = Fi - F
The force imbalance continues until the slippage limit is reached.

Problem M #10: A 10-wide flat belt is used with a driving pulley of

diameter 16 and a driven pulley of rim diameter 36 in an open
configuration. The center distance between the two pulleys is 15 feet. The
friction coefficient between the belt and the pulley is 0.80. The belt speed is
required to be 3600 ft/min. The belts are initially tensioned to 544 lbs.
Determine the following. (answers are in parentheses)
Belt engagement angle on the smaller pulley (3.03 radians).
Force in belt in the tight side just before slippage. (1000 lbs).
Maximum transmitted Hp. (99.4 hp)

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