GEARS

Introduction

Gears are considered as one of the oldest equipment known to mankind. The origin of gears goes
down to the Chinese South-Pointing Chariot in the 27th Century B.C. This chariot was known to
pointing to the south no matter how it was turned.

Aristotle has the credit to his name of giving the earliest description of gears in the 4 th century B.C.
According to his definition, the direction of rotation is reversed when one ear wheel drives another
gear wheel. Gears have been used by the Greek Inventors in water wheels and clocks. The sketches
of various types of gears of this time can be found in the notebooks of Leonardo da Vinci.

Even after these ground-breaking discoveries, no major development concerning wheels was made
until the 17th Century. In this time, first attempts were made to provide constant velocity ratios.
These attempts utilized the involute curves. This was just the beginning of something that changed
the world for all the good reasons. However, in the 19 th century, form cutters and rotating cutters
were first used and it was then in 1835 when the English inventor Whitworth patented the first gear
hobbing process.

Various other patents followed until 1897 when Herman Pfauter of Germany invented the first
hobbing machine capable of cutting both spur and helical gears. Through the 20th century, various
types of machines developed. But, the next major step came in 1975 when the Pfauter Company in
Germany introduced the first NC hobbing machine and in 1982 the Full 6 axis machine was
introduced.

Besides being used in the industry, gears are also being used in different toys and they are one of
the major components in toy cars and other toys to help them move. Even in smaller toys, gears are
used in different sizes to ensure the proper functionality of them.
Definition

A gear (also called a cogwheel) is a type of simple machine that is used to manipulate the
magnitude or direction of a force. Gears are used in combination and are linked together by
their teeth - referred to as cogs - in order to form a "gear train". These gear trains are useful for
transferring energy from one part of a system to another. Systems that utilize gears and gear
trains include bicycles, cars, electric screwdrivers, and many other common machines. Gears are
wheel-like machine elements that have teeth uniformly spaced around the outer surface. Gears can be a
fraction of an inch in diameter to a hundred feet in diameter. Gears are used in pairs and are a very
valuable design tool. They are used in everything from clocks to rockets and have been around for 3000
years.

Gears are mounted on rotatable shafts and the teeth are made to mesh (engage) with a gear on another
shaft. Gears deliver force (torque) and motion (rpm) from one part of a machine to another. Two gears
with the driven gear having twice the number of teeth of the driving gear will rotate at one-half the
speed of the driving gear and deliver twice the torque. Being able to control speed and torque by varying
the number of teeth in one gear with respect to another makes gears a valuable design tool. An
automobile transmission is an excellent example of how this principle is put to use to control vehicle
motion.

Function
Gears serve two main purposes: increasing speed or increasing force. In order
to increase one of these, compromises must me made. For example, to increase the
speed of a bicycle's wheels the force applied to the pedals must be increased. Similarly,
to increase the force on the wheels the pedals must be turned faster. This technique is
used when a rider is trying to climb a hill on a bike. This is all related to the conservation
laws of energy and power.
Gears are of common use in many systems, but can most easily be recognized in
everyday life in the cars we drive. Cars must make use of gears in order to transfer
energy from the engine to the wheels efficiently and safely. An idling engine operates at
about 1000 rpm - if the engine was connected directly to the wheels, this would mean
the car must be moving approximately 120 kph. This means if a car's engine is turned
on, it would immediately accelerate to this speed. When the engine moved into ranges
with high rpm's - around 7000 - the car would be going 840 kph! Although this seems
very fun, it is highly impractical. This is impractical due to the fact that a car requires a
large amount of energy to get moving, so an engine trying to go full speed just as it
started up wouldn't generate enough force to move the car. Therefore the car makes
use of gears in a transmission, or alternatively a "gearbox", which starts off by using
lower gears that generate more force in order to get the car moving, eventually moving
up to higher gears that focus on speed.[3]
The same principle of gears applies to bicycles; going uphill requires lower gears in
order to supply more force to counter the force of gravity, and once the rider is back on
flat land, they can switch to higher gears in order to generate more speed for their
bicycle.
How a gear works?
KINDS OF GEARS
There are a number of different types of gears. Spur gears are the most common and the easiest to
manufacture. A spur gear has teeth that are uniformly spaced around the outer surface. The teeth are
aligned in a direction that is parallel to the gear axis of rotation. A spur gear is designed to mesh with
another spur gear on a parallel shaft. The profile of the contact surface of spur gear teeth is in the form
of an involute curve. An involute curve is the path the end of a string takes when it is being unwound
from a cylinder. The shape is the easiest to manufacture and is an efficient way to transmit power
between two contacting surfaces because of the tendency to maximize rolling and minimize sliding. The
efficiency of spur gears is in the high 90% range and approaches that of anti-friction bearings.

I. SPUR GEAR
 Spur gears, also known as straight-cut gears, are the simplest and most common
type of gear. They consist of a cylinder or disk with teeth projecting radially outward,
parallel to the axis of rotation. These teeth mesh with other gears to transmit
rotational motion and torque between shafts

Here are some key characteristics of spur gears:

• Cylindrical shape: They have a cylindrical body with teeth that project outwards.
• Straight teeth: The teeth are straight and parallel to the axis of rotation, making
them simple to manufacture and relatively inexpensive.
• Parallel shafts: They mesh with other gears that have parallel shafts.
• Change in speed or torque: They can be used to change the speed or torque of a
rotating shaft. For example, a small gear can be used to drive a larger
gear, which will rotate at a slower speed but with more torque.
• Opposite direction of rotation: When two spur gears mesh, they rotate in opposite
directions.

Spur gears are available in a wide variety of sizes and materials, making them suitable
for a wide range of applications. Some common materials include:

• Steel: Strong and durable, suitable for high-power applications.

• Nylon: Lightweight and quiet, often used in low-power applications.
• Brass: Corrosion-resistant and easy to machine, often used in marine and
plumbing applications.
Here are some of the advantages and disadvantages of using spur gears:

Advantages:

• Simple and inexpensive to manufacture

• Versatile and can be used in a wide variety of applications
• Efficient at transmitting power
• Durable and can last for a long time

Disadvantages:

• Can be noisy, especially at high speeds

• Not as efficient as some other types of gears, such as helical gears
• Can be susceptible to wear and tear

Overall, spur gears are a versatile and affordable option for a wide variety of
applications. They are a good choice when simplicity, cost, and efficiency are important
factors.

NOMENCLATURE OF SPUR GEAR

 II. HELICAL GEARS
Helical gears are a type o f cylindrical gear with teeth that are cut at an angle to the
axis of rotation, resembling a screw thread. This angled design offers several
advantages over spur gears, which have straight teeth.

Here are some key features of helical gears:

 • Angled teeth: The teeth are cut at an angle to the axis of rotation, which creates
a more gradual engagement between gears. This results in smoother
operation, quieter operation, and reduced vibration compared to spur gears.
• Higher load capacity: The angled teeth also distribute the load more evenly
across the tooth surface, which increases the load-carrying capacity of helical
gears compared to spur gears.
• Parallel or non-parallel shafts: Helical gears can be used to transmit power
between shafts that are parallel, intersecting, or at an angle. This makes them
more versatile than spur gears, which can only be used with parallel shafts.
• Thrust force: The angled teeth create a thrust force along the axis of the
gear. This force needs to be accommodated by bearings in the gear system.

Here are some of the advantages of using helical gears:

• Smoother and quieter operation: The angled teeth provide a more gradual
engagement, which reduces noise and vibration.
• Higher load capacity: Helical gears can handle higher loads than spur gears of
the same size.
• More versatile: They can be used with parallel, intersecting, or angled shafts.

However, there are also some disadvantages to using helical gears:

• More complex to manufacture: The angled teeth make helical gears more
complex and expensive to manufacture than spur gears.
• Thrust force: The thrust force created by the angled teeth needs to be
accommodated by bearings, which adds complexity and cost to the gear system.
• Slightly less efficient: Helical gears are slightly less efficient at transmitting power
than spur gears due to the sliding action between the teeth.

Overall, helical gears are a good choice for applications that require smooth, quiet
operation, high load capacity, and the ability to transmit power between non-parallel
shafts. However, their higher cost and complexity compared to spur gears need to be
considered.

NOMENCLATURE OF HELICAL GEAR

Helical gears have a specific vocabulary used to describe their various parts and
dimensions. Here are some key terms in the nomenclature of helical gears:

Basic dimensions:

• Number of teeth (z): The total number of teeth on the gear.

• Normal module (mn): A measure of the tooth size based on the pitch diameter
and number of teeth.
• Normal pressure angle (αn): The angle between the normal to the tooth profile
and the line tangent to the pitch circle.
• Helix angle (β): The angle of the teeth relative to the axis of rotation. This can be
positive (right-hand) or negative (left-hand).
• Hand: Refers to the direction of the helix angle, either right-hand (RH) or left-
hand (LH).
• Addendum (a): The distance between the top of the tooth and the pitch circle.
• Dedendum (b): The distance between the bottom of the tooth space and the pitch
circle.
• Pitch diameter (dp): The diameter of a circle that represents the average location
of the contacting tooth surfaces.
• Base diameter (db): The diameter of a circle tangent to the bottoms of the tooth
spaces.
• Tip diameter (dt): The diameter of a circle tangent to the tops of the teeth.
• Center distance (a): The distance between the centerlines of the mating gears.

Additional terms:
 • Normal tooth thickness (sn): The thickness of a tooth measured along the normal
to the profile.
• Transverse tooth thickness (st): The thickness of a tooth measured on the pitch
circle.
• Circular tooth thickness (sc): The thickness of a tooth measured on a circle
concentric with the pitch circle and passing through the tooth tips.
• Axial pitch (p): The distance along the helix between corresponding points on
adjacent teeth.
• Transverse pitch (pt): The distance between corresponding points on adjacent
teeth measured on the pitch circle.
• Normal pitch (pn): The distance between corresponding points on adjacent teeth
measured along the normal to the profile.
• Lead angle (ψ): The angle between the helix angle and the plane perpendicular
to the axis of rotation.
• Contact ratio: The ratio of the length of the path of contact between two meshing
teeth to the normal pitch.
III. WORM GEAR
A worm gear is a type of gear that consists of a worm, which is a screw-shaped gear,
and a worm wheel, which is a toothed wheel that meshes with the worm. Worm
gears are typically used to change the direction of rotation between two shafts, as
well as to provide a high gear reduction.

Here are some key features of worm gears:

• Worm and worm wheel: The two main components of a worm gear are the worm
and the worm wheel. The worm is a screw-shaped gear, while the worm wheel is
a toothed wheel that meshes with the worm.
• Right-angle or near right-angle shafts: The shafts of the worm and worm wheel
are typically at a right angle or near right angle to each other.
 • High gear reduction: Worm gears can provide a very high gear
reduction, meaning that the output shaft will rotate much slower than the input
shaft. This is because there are many more teeth on the worm wheel than there
are threads on the worm.
• Self-locking: Worm gears are self-locking, meaning that the worm cannot drive
the worm wheel in the opposite direction. This is because the angle of the teeth
on the worm wheel is greater than the angle of the threads on the worm.

Here are some of the advantages of using worm gears:

• High gear reduction: Worm gears can provide a very high gear reduction in a
small space.
• Self-locking: Worm gears are self-locking, which can be helpful in applications
where it is important to prevent the output shaft from rotating in the opposite
direction.
• Smooth operation: Worm gears can provide smooth and quiet operation.

However, there are also some disadvantages to using worm gears:

• Lower efficiency: Worm gears are less efficient than other types of gears, such
as spur gears or helical gears. This is because there is a lot of sliding friction
between the worm and the worm wheel.
• Higher cost: Worm gears can be more expensive to manufacture than other
types of gears.
• Limited speed: Worm gears are not suitable for high-speed applications.

Overall, worm gears are a versatile type of gear that can be used in a wide variety of
applications. They are a good choice when high gear reduction, self-locking, or smooth
operation are important factors. However, their lower efficiency, higher cost, and limited
speed need to be considered.

NOMECLATURE OF WORM GEAR

Worm gears have their own set of terms specific to their unique design. Here's a
breakdown of their key nomenclature:

Basic dimensions:

• Number of threads (z): Similar to teeth in spur gears, this refers to the number of
helical threads on the worm.
• Normal module (mn): Similar to helical gears, this defines tooth size based on
pitch diameter and number of threads.
• Lead angle (γ): The angle of the threads relative to the axis of the
worm, determining worm gear reduction ratio.
• Hand: Similar to helical gears, refers to the direction of the lead angle (right-hand
or left-hand).
• Addendum (a): Distance between the top of the thread and the pitch circle.
• Dedendum (b): Distance between the bottom of the worm groove and the pitch
circle.
• Pitch diameter (dp): Diameter of a circle representing the average contact point
of threads and wheel teeth.
• Throat diameter (Dt): Diameter at the base of the thread groove, smaller than the
pitch diameter.
• Center distance (a): Distance between the centerlines of the worm and wheel.

Worm wheel:

• Number of teeth (Z): Total number of teeth on the worm wheel.

• Normal module (mn): Same as the worm module for proper meshing.
• Pressure angle (α): Similar to helical gears, defines the angle between tooth
profile and pitch line.
• Face width (b): Width of the worm wheel measured along the axis of rotation.

Additional terms:

• Axial pitch (p): Distance along the worm thread between corresponding points.
• Normal pitch (pn): Distance between corresponding points on worm and wheel
measured along the normal to the profile.
• Lead (L): Distance a point on the worm travels axially in one revolution.
 • Reduction ratio (i): Ratio of worm wheel teeth to worm threads, determining
speed and torque change.
• Self-locking angle (λ): Angle between worm thread and wheel tooth
profile, impacting self-locking behavior.

IV. BEVEL GEAR

Bevel gears are a type of gear used to transmit rotational power between intersecting
shafts, typically at 90 degrees. They have conical shapes with teeth that mesh
together, allowing for smooth power transfer at an angle.

Here are some key features of bevel gears:

• Conical shape: Their unique shape allows them to connect shafts at various
angles, most commonly 90 degrees but also other angles based on design.
• Angled teeth: The teeth are cut at an angle to match the conical shape, ensuring
proper meshing with the mating gear.
• Shaft angles: They can be used with shafts at various angles, including 90
degrees, but also non-standard angles for specific applications.
• Speed and torque changes: Like other gears, they can change the speed and
torque of the output shaft. The ratio of the gear teeth determines this change.

Bevel gears come in different types, each suited for specific applications:

• Straight bevel gears: These have straight teeth, offering simple designs and
affordability, but with higher noise levels.
 • Spiral bevel gears: These have curved, helical teeth, providing smoother
operation, quieter running, and higher load capacity than straight bevel gears.
• Zerol bevel gears: A special type of spiral bevel gear with teeth designed to
cancel out thrust forces, improving efficiency and bearing life.
• Hypoid gears: These have offset axes, allowing for higher contact ratios and
smoother operation than standard bevel gears, but they are more complex and
expensive.

Here are some advantages of using bevel gears:

• Change shaft direction: They efficiently transmit power between shafts at

angles, especially 90 degrees.
• Compact design: Their conical shape allows for space-saving designs in tight
applications.
• Variety of choices: Different types cater to various needs for
noise, efficiency, load capacity, and cost.

However, there are also some disadvantages to using bevel gears:

• Complexity: Compared to spur gears, their manufacturing process can be more

complex, increasing cost.
• Friction: Sliding contact between teeth can generate friction and heat, reducing
efficiency.
• Noise: Straight bevel gears can be noisy, while even quieter options might not be
as silent as other gear types.

Overall, bevel gears are valuable components in various mechanical systems, offering
efficient power transmission at angles. Their diverse types and characteristics make
them suitable for a wide range of applications, from car differentials to power tools and
textile machinery.

NOMENCLATURE OF BEVEL GEAR

The nomenclature of bevel gears can be quite specific, encompassing various aspects
of their geometry and functionality. Here's a breakdown of key terms:

General terms:

• Number of teeth (z): Total number of teeth on the gear.

• Normal module (mn): Ratio of pitch diameter to the number of teeth, defining
tooth size.
• Pressure angle (α): Angle between the tooth profile and the pitch line, affecting
contact and strength.
• Center distance (a): Distance between the centerlines of mating bevel gears.
• Shaft angle: Angle between the input and output shafts, typically 90° for standard
bevel gears.
• Hand: Refers to the direction of rotation, either right-hand (RH) or left-hand (LH).

Geometry-related terms:

• Pitch cone: Imaginary cone defining the tooth profile, with its apex at the shaft
intersection.
• Pitch diameter (dp): Diameter of a circle on the pitch cone representing the
average contact point of teeth.
• Crown diameter (Dc): Largest diameter of the pitch cone, determining overall
size.
• Root diameter (Dr): Smallest diameter of the pitch cone, defining the base of the
teeth.
• Face width (b): Width of the gear measured along the shaft axis.
 • Cone angle (β): Angle between the pitch cone generatrix and the axis of rotation.
• Addendum (a): Distance between the top of the tooth and the pitch circle.
• Dedendum (b): Distance between the bottom of the tooth space and the pitch
circle.

Specific terms for different bevel gear types:

• Straight bevel gear: Simple design with straight teeth, offering affordability but
with higher noise.
o Spiral bevel gear: Curved teeth providing smoother operation, quieter
running, and higher load capacity.
o Zerol bevel gear: Special spiral bevel gear with teeth designed to cancel
thrust forces, improving efficiency and bearing life.
o Hypoid gear: Offset axes for higher contact ratios and smoother
operation, but more complex and expensive.

Additional terms:

• Back cone angle: Angle between the back of the tooth and the axis of rotation.
• Contact ratio: Ratio of the length of the path of contact between two meshing
teeth to the pitch line.
• Overlap ratio: Ratio of the active tooth height to the total tooth height.
• Clearance angle: Angle between the face of the tooth and the pitch cone.
• Bevel gear ratio (i): Ratio of the driver gear teeth to the driven gear
teeth, determining speed and torque changes.
CLASSIFICATION OF GEARS ACCORDING TO THE NATURE OF AXIS
I. Parallel axis
a. External Spur Gear

An external spur gear is a type of gear with teeth that project outwards from the cylindrical body
of the gear. They are the most common type of gear and are used in a wide variety of
applications, from bicycles and clocks to washing machines and power tools.
Here are some of the key features of external spur gears:

• Straight teeth: The teeth of an external spur gear are straight, parallel to the axis
of rotation. This makes them simple to manufacture and relatively inexpensive.
• Meshed with other gears: They can mesh with other external spur gears, as well
as with internal spur gears.
• Opposite direction of rotation: When two external spur gears mesh, they rotate in
opposite directions.
• Change in speed or torque: They can be used to change the speed or torque of a
rotating shaft. For example, a small gear can be used to drive a larger
gear, which will rotate at a slower speed but with more torque.

External spur gears are available in a wide variety of sizes and materials, so they can
be used in a wide range of applications. Some common materials for external spur
gears include steel, nylon, and brass.

Here are some of the advantages of using external spur gears:

• Simple and inexpensive to manufacture

• Versatile and can be used in a wide variety of applications
• Efficient at transmitting power
• Durable and can last for a long time

However, there are also some disadvantages to using external spur gears:
 • Can be noisy, especially at high speeds
• Not as efficient as some other types of gears, such as helical gears
• Can be susceptible to wear and tear

Overall, external spur gears are a versatile and affordable option for a wide variety of
applications. They are a good choice when simplicity, cost, and efficiency are important
factors.

b. Internal spur gear

Internal spur gears are a fascinating type of gear that offer unique advantages in certain
applications. Here's a breakdown of their key features and considerations:

Key features:

• Teeth on the inside: Unlike standard spur gears with teeth on the outside, internal
gears have their teeth cut inside a cylindrical body.
• Mates with external spur gears: They mesh with external spur gears, typically of
a smaller size.
• Higher contact ratio: This design allows for a larger contact area between the
gears, leading to a higher contact ratio and potentially smoother
operation and higher load capacity.
• Compact design: Due to the smaller external diameter, they can offer a more
compact design compared to external spur gears with the same number of teeth.
• Self-locking potential: In some configurations, they can exhibit self-locking
behavior, meaning the external gear cannot drive the internal gear in the
opposite direction.

Considerations:

• Manufacturing complexity: The internal teeth make them more complex and
expensive to manufacture than external spur gears.
• Limited power handling: Their inherent design limits their ability to
handle extremely high power compared to some other gear types.
• Higher thrust loads: The meshing action can create higher thrust loads on the
bearings compared to external spur gears.

Applications:
 • Planetary gear trains: They are frequently used in planetary gear trains, where
their compact design and potential for self-locking are advantageous.
• Speed reducers: They can be used in speed reducers where a high gear ratio
and space constraints are factors.
• Indexing mechanisms: Their self-locking potential can be useful in indexing
mechanisms where precise positioning is required.

c. Twisted spur gear

helical gears are the most likely interpretation of "twisted spur gear." They have teeth
that are cut at an angle (the helix angle) to the axis of rotation, resembling a screw
thread. This design offers several advantages over traditional spur gears, including:

• Smoother operation and quieter noise: The angled teeth create a more gradual
engagement, reducing noise and vibration.
• Higher load capacity: The angled teeth distribute the load more evenly across the
tooth surface, allowing them to handle higher loads than spur gears of the same
size.
• Parallel or non-parallel shafts: Helical gears can be used with
parallel, intersecting, or angled shafts, providing more versatility than spur gears.

However, helical gears are distinct from spur gears in that their teeth still project
outwards from the cylinder, unlike internal spur gears.

In some instances, "twisted spur gear" might be a misinterpreted or informal term

for internal spur gears. These gears have their teeth machined on the inside of a
cylindrical body, meshing with an external spur gear of smaller size. They offer
 advantages like a higher contact ratio and potentially self-locking behavior, but
are more complex to manufacture and have limitations in power handling.

d. Herringbone gear
A herringbone gear is a specific type of double helical gear. It's essentially a
combination of two helical gears placed side-by-side with opposite hand
orientations. Each helical section has its teeth angled in opposite directions,
resembling the letter "V" when viewed from the top. These "V" grooves, when
combined, form a distinctive herringbone pattern similar to the bones of a fish,
hence the name.

Here are some key features of herringbone gears:

• Parallel Axis: They are designed to transmit power between parallel

shafts, similar to helical gears.
• Double Helical Teeth: Their unique feature lies in the combination of two helical
gear sections with opposite hand orientations, creating the characteristic
herringbone pattern.
• Balanced Axial Thrust: The opposing helix angles effectively cancel out the axial
thrust forces generated by each individual helical section. This eliminates the
 need for additional thrust bearings, simplifying the design and reducing noise and
vibration.
• Smooth Operation: Similar to helical gears, the angled teeth provide a more
gradual engagement compared to spur gears, resulting in smoother
operation, reduced noise, and higher load capacity.

Here's a comparison of herringbone gears with other gear types:

Feature Spur Gear Helical Gear Herringbone Gear

Angled (double
Tooth Profile Straight Angled
helical)

Shaft Parallel or non-

Parallel Parallel
Alignment parallel

Axial Thrust Unbalanced Balanced Balanced

Noise &
High Moderate Low
Vibration

Load Capacity Low Moderate High

Complexity Low Moderate High

drive_spreadsheetExport to Sheets

Applications:

Herringbone gears are widely used in various applications due to their smooth
operation, high load capacity, and balanced thrust forces. Some common applications
include:

• Gearboxes: In transmissions of automobiles, motorcycles, and industrial

machinery.
• Machine tools: Used to drive spindles and feed mechanisms in milling
machines, lathes, and other equipment.
• Power generation: Employed in wind turbines and other high-power applications.
 • Marine propulsion: Utilized in ship engines and gearboxes for smooth and
efficient power transmission.
e. Rack and Pinion
Rack and pinion is a type of linear actuator that converts rotary motion into linear
motion, or vice versa. It consists of two main components:

1. Rack: A straight bar with evenly spaced teeth along one side.

2. Pinion: A circular gear that meshes with the teeth of the rack.

When the pinion rotates, it drives the rack along its length, converting the rotary motion
into linear motion. Conversely, moving the rack linearly will cause the pinion to rotate,
converting linear motion into rotary motion.

Here are some key features and applications of rack and pinion systems:

Features:

• Simple and efficient design: Relatively easy to manufacture and maintain.

• High precision: Offers accurate and controlled linear motion.
• Self-locking in some configurations: Certain designs prevent the rack from
moving backward when the pinion is not powered.
• Compact design: Can be suitable for applications with limited space.

Applications:

• Steering systems: Commonly used in cars and other vehicles to convert steering
wheel rotation into wheel turning.
• Machine tools: Employed in various machines for precise movement of
slides, tables, and other components.
• Elevators and lifts: Used to raise and lower platforms and carriages.
• Doors and gates: Employed for opening and closing automatic doors and gates.
• Dental flossers: The mechanism that extends and retracts the floss.

Advantages:

• Simple and cost-effective design

• Versatile and suitable for various applications
 • Offers high precision and control
• Can be self-locking for added safety in some cases

Disadvantages:

• Lower load capacity compared to some other linear actuators

• Can be less efficient at high speeds due to sliding friction
• May require additional components for lubrication and bearing support

Overall, rack and pinion systems are a popular and versatile choice for applications
requiring precise and controlled linear motion. Their simple design, efficiency, and wide
range of applications make them a valuable tool in various industries.

f. Pin gear
The term "pin gear" can be ambiguous and refer to several different things depending on
the context. Here are some possible interpretations:

1. Pinion gear: This is the most common use of the term "pin gear." It simply refers to a
small gear that meshes with a larger gear, typically in a rack and pinion system. In this
case, "pin" is not referring to a physical pin but rather the smaller size of the gear.

2. Pin drive gear: This type of gear has a central pin that engages with slots or holes in
the mating gear. This design allows for some misalignment between the shafts and is
used in applications like wind turbine gearboxes.

3. Tsubaki Pin Gear Drive Unit: This is a specific brand name for a gear transmission
system that uses rollers and a rack instead of traditional teeth. It offers high torque
capacity and compact design.

4. Informal term: In some cases, "pin gear" might be an informal or imprecise term used
for various gear types depending on the specific context.
 II. INTERSECTING AXIS
A. PLAIN BEVEL GEAR

Plain bevel gears are a specific type of bevel gear known for their simple design and
affordability. Here's a breakdown of their key features and considerations:

Key features:

• Straight teeth: Unlike other bevel gears like spiral or zerol bevel gears, plain
bevel gears have straight teeth that are parallel to the gear's axis. This simplifies
their manufacturing process but comes with some drawbacks.
• Perpendicular shafts: They are typically used with shafts intersecting at 90
degrees, although other angles are possible in specific designs.
• Lower cost: Due to their simple design and straight teeth, plain bevel gears are
generally more affordable than other bevel gear types.
• Lower load capacity: The straight teeth generate higher contact stress compared
to angled teeth, resulting in a lower load capacity compared to other bevel gears.
• Higher noise and vibration: The sliding action between straight teeth
causes more noise and vibration compared to gears with angled teeth.

Considerations:

• Applications: Plain bevel gears are suitable for low-speed and low-torque
applications where cost and simplicity are important factors. They are often used
in:
o Agricultural machinery
o Textile machinery
o Conveyor systems
 o Light-duty gearboxes
• Alternatives: For higher load capacity, smoother operation, and quieter
performance, other bevel gear types like spiral or zerol bevel gears might be a
better choice.

Additional notes:

• Plain bevel gears can be manufactured with various tooth profiles, such as full
depth or stub depth, depending on the specific application requirements.
• They are sometimes referred to as straight bevel gears or non-spiral bevel gears.
B. CROWN BEVEL GEAR

Crown bevel gears, also known as face gears or contrate gears, are a specific type of
bevel gear characterized by their unique tooth design and functionality. Here's a
breakdown of their key features and considerations:

Key features:

• Internal teeth: Unlike standard bevel gears with teeth on the outside, crown gears
have their teeth cut on the inside of a cylindrical body. This design allows for a
more compact footprint and potentially higher contact ratios.
• Mates with external bevel gears: They typically mesh with external bevel
gears, often of a smaller size.
• High contact ratio: Due to the larger area engaged by the internal teeth, they can
achieve a higher contact ratio compared to external bevel gears, potentially
leading to smoother operation and higher load capacity.
• Compact design: The internal teeth design allows for a more compact radial
dimension compared to external bevel gears with the same number of teeth.
• Potential for self-locking: In some configurations, they can exhibit self-locking
behavior, meaning the external gear cannot drive the crown gear in the opposite
direction.

Considerations:

• Manufacturing complexity: The internal teeth make them more complex and
expensive to manufacture than external bevel gears.
• Limited power handling: Their inherent design often limits their ability to
handle extremely high power compared to some other gear types.
• Higher thrust loads: The meshing action can create higher thrust loads on the
bearings compared to external bevel gears.
Applications:

• Planetary gear trains: They are frequently used in planetary gear trains, where
their compact design and potential for self-locking are advantageous.
• Speed reducers: They can be used in speed reducers where a high gear ratio
and space constraints are factors.
• Indexing mechanisms: Their self-locking potential can be useful in indexing
mechanisms where precise positioning is required.
• Differential assemblies: Crown gears can be found in the differential assemblies
of some all-wheel-drive vehicles, where they transmit power and manage torque
distribution between axles.

Additional notes:

• Crown bevel gears can be manufactured with various tooth profiles, such
as straight or spiral, depending on the specific application requirements.
• They are sometimes referred to as internal bevel gears.
C. SPIRAL BEVEL GEAR

Spiral bevel gears are a popular choice for transmitting power between intersecting
shafts, renowned for their smooth operation, higher load capacity, and quieter
performance compared to their straight-toothed counterparts. Let's delve into the
specifics:

Key Features:

• Curved Teeth: Unlike straight bevel gears, their teeth have a helical form,
resembling a screw thread. This unique design offers several advantages:

o Smoother Engagement: The gradual meshing of curved teeth reduces

noise and vibration, providing quieter operation.
o Higher Load Capacity: The angled contact distributes forces more evenly
over the tooth surface, allowing for higher torque transmission compared
to straight bevel gears.
o Reduced Axial Thrust: The angled teeth generate thrust forces that
partially cancel each other out, leading to reduced stress on bearings and
improved efficiency.

• Shaft Angles: These gears typically function with shafts intersecting at 90

degrees, but can also be designed for other angles depending on the application.
 • Right-Hand and Left-Hand: They come in right-hand and left-hand versions,
determined by the direction of the helix angle. This allows for flexible design
configurations.

Advantages:

• Smooth and quiet operation: Ideal for applications requiring quiet and vibration-
free power transmission.
• Higher load capacity: Suitable for demanding applications with high torque and
speed requirements.
• Reduced wear and tear: The smoother operation and even load distribution
contribute to extended gear life.
• Versatility: Adaptable to various shaft angles and operating conditions.

Disadvantages:

• Higher cost: The more complex manufacturing process compared to straight

bevel gears leads to slightly higher cost.
• Thrust forces: While reduced compared to straight bevel gears, residual thrust
forces still need to be accommodated by bearings.

Applications:

• Automotive differentials: Widely used in car differentials to transmit power and

manage torque distribution between axles.
• Gearboxes: Employed in various gearboxes across industries for efficient power
transmission and speed changes.
• Machine tools: Found in machine tools for smooth and precise control of spindle
and feed mechanisms.
• Agricultural machinery: Utilized in various agricultural equipment for reliable
power transmission under moderate loads.
• Construction equipment: Employed in construction machinery for robust power
transfer in demanding environments.

Additional Notes:

• Spiral bevel gears come in various types, including Zerol gears with optimized
teeth for further reduced thrust forces and hypoid gears with offset axes for
higher contact ratios.
 • Specific terms and definitions might vary depending on the standard and source
you're referencing.
III. NON-INTERSECTING OR NON-PARALLEL AXIS
A. HYPERBOLOIDAL

"Hyperboloidal" refers to a geometric shape rather than a specific gear type. However,
in the context of gears, it signifies the use of hyperboloids in gear design, leading to a
special type of gear called a hyperboloidal gear.

Here's what you need to know about hyperboloidal gears:

Concept:

• Hyperboloidal gears have teeth generated by the intersection of a straight line

with a hyperboloid, a 3D surface with two curved sheets extending outwards from
a central point.
• Unlike traditional gears with cylindrical or conical shapes, the teeth of
hyperboloidal gears have a curved and twisted profile.

Key features:

• Non-parallel shafts: They can connect shafts at any angle, including non-parallel
ones, offering greater flexibility than standard gears.
• Constant line contact: Their unique tooth design provides a continuous line
contact between the meshing gears, leading to smoother operation and
potentially higher load capacity.
• Self-locking potential: In some configurations, they can exhibit self-locking
behavior, preventing the driven gear from rotating in the opposite direction.

Advantages:

• Versatility: Can handle non-parallel shaft angles, making them suitable for
complex transmission systems.
• Smooth operation: Line contact offers quieter and smoother operation compared
to traditional gears.
• Self-locking: Potentially beneficial for applications requiring unidirectional
rotation.

Disadvantages:
 • Manufacturing complexity: The complex tooth design makes them more
challenging and expensive to manufacture compared to other gear types.
• Limited availability: Not as widely available as standard gears due to their
complexity.
• Higher sensitivity: Might be more sensitive to alignment and manufacturing
tolerances.

Applications:

• Specialized transmissions: Used in niche applications with non-parallel shaft

angles, such as certain machine tools and robotic systems.
• Research and development: Employing hyperboloidal gears for their unique
properties in research and development projects.

Comparison to other gear types:

• Spiral bevel gears: Offer similar advantages in smooth operation and higher load
capacity but are limited to 90° or near-90° shaft angles.
• Worm gears: Can also achieve self-locking but with lower efficiency and higher
friction.

Overall:

Hyperboloidal gears are a fascinating and specialized type of gear offering unique
advantages for specific applications. Their complex design makes them less common
than standard gears, but their potential for efficient and versatile power transmission in
unique configurations continues to attract interest.

B. HYPOID
 "hypoid" refers to a specific type of gear derived from the concept of
hyperboloidal gears, offering unique advantages and applications. Here's a detailed
breakdown:

Hypoid Gears: Unveiling the Offset Advantage for Power Transmission

Hypoid gears are a special type of spiral bevel gear characterized by offset axes. This
unique design grants them distinct advantages in applications requiring high torque
transmission and non-parallel shaft angles.

Key Features:

• Offset Axes: Unlike standard bevel gears with intersecting axes, hypoid gears
have axes that are slightly offset. This allows them to connect shafts at non-
parallel angles, typically ranging from 15° to 45°.
• Hyperboloidal Tooth Surfaces: While related to hyperboloidal gears, their teeth
are not true hyperboloids but rather a combination of hyperbolic and conical
sections. This optimized design provides a good balance between contact
ratio, load capacity, and manufacturing complexity.
• Line Contact: Similar to hyperboloidal gears, they achieve line contact between
the meshing teeth, promoting smoother operation and higher load capacity
compared to point contact gears.
• Partial Self-Locking: In some configurations, they exhibit partial self-
locking, where high torque in one direction can prevent reverse rotation.

Advantages:

• Non-parallel shaft angles: The offset axes enable flexible power transmission
between shafts at angles beyond the 90° limit of standard bevel gears.
• High torque capacity: The line contact and optimized tooth design contribute to
higher load capacity compared to some bevel gears.
• Smoother operation: The rolling action and line contact lead to quieter and
smoother operation compared to gears with point contact.
• Partial self-locking: Can be beneficial for applications requiring unidirectional
rotation without a separate locking mechanism.

Disadvantages:

• Manufacturing complexity: The offset axes and curved tooth profiles make them
more complex and expensive to manufacture than standard bevel gears.
 • Higher sensitivity: They can be more sensitive to alignment and manufacturing
tolerances compared to simpler gear types.
• Limited availability: Due to their complexity, they are not as readily available as
standard bevel gears.

Applications:

• Automotive differentials: Widely used in car differentials to transmit power and

manage torque distribution between axles, even when the axles are not perfectly
aligned.
• Industrial gearboxes: Employed in various industrial gearboxes where high
torque transmission and non-parallel shaft angles are necessary.
• Agricultural machinery: Utilized in some agricultural equipment, such as
tractors, for their robust power transfer and ability to handle misalignments.
• Specialized applications: Found in niche applications demanding unique
combinations of high torque, non-parallel shafts, and smooth operation.

Comparison to other gear types:

• Spiral bevel gears: Offer similar advantages in smooth operation and load
capacity but are limited to 90° or near-90° shaft angles.
• Worm gears: Can achieve high torque and self-locking but with lower efficiency
and higher friction.
• Hyperboloidal gears: Share the non-parallel shaft capability but are even more
complex and less readily available.

Overall:

Hypoid gears represent a clever engineering solution, providing high torque

transmission between non-parallel shafts with smoother operation and partial self-
locking potential. Their complexity makes them less common than standard gears, but
their unique characteristics hold value in various demanding applications.
 C. SCREW GEAR

The term "screw gear" can be ambiguous and refer to two different things:

1. Helical Gear: This is the most common interpretation of "screw gear." Helical gears
have teeth cut at an angle to the axis of rotation, resembling a screw thread. This
design offers several advantages over traditional spur gears, including:

• Smoother operation and quieter noise: The angled teeth create a more gradual
engagement, reducing noise and vibration.
• Higher load capacity: The angled teeth distribute the load more evenly across the
tooth surface, allowing them to handle higher loads than spur gears of the same
size.
• Parallel or non-parallel shafts: Helical gears can be used with
parallel, intersecting, or angled shafts, providing more versatility than spur gears.

However, helical gears typically still have teeth on the outside of a cylindrical body,
unlike the next interpretation of "screw gear."

2. Worm Gear: A worm gear consists of a shaft with a helical thread (worm) that
meshes with a gear (worm wheel) having angled teeth. This design allows for high gear
ratios and self-locking behavior, meaning the worm can drive the wheel but not vice
versa. However, worm gears have lower efficiency and higher friction compared to other
gear types.