Article citation info: 1

Krol O, Sokolov V, Golubenko A. Modification of rack-and-pinion transmission design with increased resource. Diagnostyka.
2022;23(1):2022105. https://doi.org/10.29354/diag/145967.

1 e-ISSN 2449-5220
DIAGNOSTYKA, 2022, Vol. 23, No. 1
DOI: 10.29354/diag/145967

MODIFICATION OF RACK-AND-PINION TRANSMISSION DESIGN

WITH INCREASED RESOURCE

Oleg KROL, Volodymyr SOKOLOV, Aleksander GOLUBENKO

Volodymyr Dahl East Ukrainian National University, Department of Machinery Engineering and Applied
Mechanics, 59-a Central pr., Severodonetsk, 93400, Ukraine
e-mail: [email protected]

Abstract
In this paper, the mechanism of a slotting spindle head for the implementation of rectilinear motion based
on a rack and pinion is considered. A three-dimensional modeling procedure of the slotting head elements for
a multioperational machine tool of the drilling-milling-boring type has been carried out. 3D models of the rack
and pinion were built in the integrated CAD KOMPAS using its built-in geometric core. An assessment of the
stress-strain state in the engagement zone is given using the finite element method. The concept of increasing
the load capacity due to the proposed version of the teeth envelope surface with curved axoids is analyzed. An
analytical apparatus for determining the basic design parameters of a rack and pinion transmission modified
version is proposed. The calculation of the geometric parameters for the end profile of the gearing teeth is
experimentally realized, taking into account the found value of the disk milling cutter diameter for teeth cutting
by the copying method.

Keywords: rack bar, solid model, basic rack profile, load capacity, curvilinear axoids.

1. INTRODUCTION One of the research areas is a comprehensive

analysis of the nature and conditions of gearing, as
Rack-and-Pinion Transmission (RPT) is used on the basis for the implementation of a complex
CNC machines to convert the reciprocating motion geometric-kinematic study of the RPT mechanism.
of the rack into the rotary motion of the pinion, and
vice versa. The machining of rather large machine 2. LITERATURE REVIEW
parts, which do not have high requirements for
accuracy, is its area of application. The advantages Several works [5-7] are devoted to the study of
of the RPT are its high efficiency (up to 99%), the functioning of the rack and pinion gear and the
resistance to stress, ease of operation and low stress-strain state of its elements.
susceptibility to contamination. Another option is to In work [5] the complex approach to an
use it in interchangeable modular tooling of estimation of the dynamic quality of RPT-
multioperational machines to increase its functioning and level of contact and bending stresses
technological capabilities [1-3]. in a zone of rack and gear wheel engagement is
When designing rack-and-pinion transmission, offered. At the initial stage of the research, 3D
one of the main requirements is to ensure strength models of the RPT elements were built in the
characteristics with minimum dimensions. To Unigraphics system. On this basis, research on the
research the RPT strength characteristics, using transmission dynamics in the system ANSYS was
calculation forms RF-02-25 [4], intended to conducted and a set of natural frequencies of
determine the static bending stress strength. For RPT vibrations outside the resonance zone was
heavily loaded engagement – the rack is checked for determined. Using the finite element method, the
bearing stress. However, the considered formulas do diagrams (fields) of the equivalent contact and
not give an idea of the full picture of the stress-strain bending stresses in the gearing zone have been
state of the RPT elements, the balance of various obtained. It is shown that the maximum level of
stress components in the rack tooth cross-sections stresses (in quantitative form) is located near the
and stress concentration zones. teeth addendum surface, outside the meshing zone,
The high level of stresses and strains in the and the thesis about the necessity of modification of
process of functioning makes it necessary to search the toothed profile design is stated.
for ways of improving the design of the RPT In [6] a rotary machine with a driving device in
elements and the technology of their manufacturing. the form of a toothed rack and pinion mechanism is

© 2022 by the Authors. Licensee Polish Society of Technical Diagnostics (Warsow. Poland). This article is an open
access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license
http://creativecommons.org/licenses/by/4.0/).
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considered. The work of the given mechanism of stresses on the flank surfaces of the rack and
analysis based on the built 3D model in the ANSYS pinion teeth are proposed.
system is carried out. The picture of contact and In many works [12-14] it is necessary to realize
bending stresses distribution along the tooth profile at the initial stages of research to improve the toolkit
is presented. The places of deformation description of the tooth flank surface contour of the
concentration in the contact zone and the area of the wheel. Such a description will be the basis for
tooth dedendum are revealed. To improve the service obtaining optimized contact conditions in a wide
life of the RPT, the authors [6] propose to use range of gearing functioning. The study of contact
aluminums alloys and composites as gear material, lines, the curvature of working surfaces and
which are characterized by a lower level of localization of contact in works [12, 13] were
deformation in the contact zone. At the same time, considered. According to [14], one of the main goals
the issues of improving the design of the rack-and- at the initial stage is to create a working 3D model to
pinion mechanism are not considered in this work. analyze the contact geometry, visual identification
In the fundamental study [7] the mechanical and evaluation of the ratios of many tooth geometric
system Rack-and-Pinion steering system (RPS), parameters. The important parameters include
which is modeled using multibody modelling of the groove profile characteristics, which are largely
system (MBS) [7, 8]. The links between the elements determined by the shape of the longitudinal
of the system are mapped using kinematic generatrix of the pinion and wheel axoids.
constraints (joke assembly, tie rods) and force Thus, a method of creating a three-dimensional
elements (pressure spring). As the core of MBS, the model of gear transmissions in the relevant
authors have developed a set of computational integrated CAD [15, 16] should be included in the
algorithms based on the equations of motion – rack designer's toolkit. The integrated CAD system
rolling in longitudinal rack axis when engagement KOMPAS-3D [17, 18] with application libraries and
with a gear wheel. The use of the reverse engineering APM Graph module for parametric modeling of
toolkit [7] is very effective for determining the shafts and mechanical gears is promising in this
geometric characteristics and constructing a model regard.
of elastic contact interaction. A distinctive feature of Based on the analysis of the functioning process
the proposed research [7] is the introduction of the of RPT-mechanisms and the existing results, let's
RPS Coordinate measuring machine to obtain carry out the statement of the research problem: to
estimates of its functional behavior taking into develop an improved design of the rack-and-pinion
account the measured geometry of the rack gear. On transmission with an increased resource using the
this basis, a new functional test for assessing the toolkit of three-dimensional and parametric
quality of the rack and pinion gearing is modeling in the KOMPAS-3D system.
implemented. To achieve this goal, it is proposed:
In the same respect, the work [9] is of interest. 1. To create three-dimensional models of the RPT
On the example of toothed belt transmission, a for multi-operating machine tool using the
device has been developed to measure the author's parametric kernel of the ARM Graph
parameters of a toothed belt and changes in its module and to research the rack stress-strain state
transverse and longitudinal profile are assessed. of the RPT-mechanism by the finite element
Measurements along the axis are performed method.
continuously and controlled by an application called 2. Develop analytical apparatus for calculating the
DiagBeltSonic, specially developed for this purpose. main technical characteristics of the modified
The application allows the designer to determine RPT design with increased service life.
some basic information about the structure of the
main gear elements before testing. It is also 3. 3D AND PARAMETRIC MODELING OF
important to equip gear production with appropriate RPT-MECHANISM AND RESEARCH OF
CAM software systems. Promising in this regard is THE STRESS-STRAIN STATE
the Gleason 5-axis Gear Studio (G5S) [10] software
from Gleason Corporation. These specialized 3.1. Design of a slotting spindle head
programs are designed for tooth flank profiling, A Rack-and-pinion transmission is used in
contact pattern evaluation, and preparation of planning, gear slotting machines and machining
appropriate control programs for 5-axis CNC centers to convert the rotational motion of the
machines and machining centers. driving link into a straight motion of the driven link.
Issues of loading level analysis of RPS pinion at Machining centers of the drilling and milling and
high gear ratios and limited dimensions of RPS- boring group with a horizontal spindle (structural
mechanism using multibody modelling apparatus are formula of which is XYZOĈh are using a variety of
also considered in [11]. The constructive variant of modular equipment [19, 20]. To increase the number
the small-diameter pinion with a reduced number of of technological modules and increase the degree of
teeth and transmission correction associated with an use of the layout structure overhead heads, turning
increase in friction forces is analyzed in this paper. devices, as well as a slotting head (SH) are used. The
Technological and structural ways of torque SH kinematic scheme is shown in Fig. 1, a.
reduction on the actuator RPS and reducing the level
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In the SH-design (Fig. 1, b) which is mounted on a geometric model and calculate the geometric
the horizontal spindle headstock with the help of four characteristics of the simulated object. The new
screws, gear-and-rack transmission is used. The SH version of the C3D Modeler used in this research
drive is realized from the main motion drive shaft includes functionality to remove holes and rounding
through the cam clutch, gear transmission and then from the model (Fig. 2, b). This leads to a simplified
through the connecting link mechanism which the representation of the 3D model, which is prepared
follower is connected to the ram performing a double for further calculation in the CAE system [23, 24].
pass (dp) per one-wheel revolution of the connecting Another application of the new function is a
link mechanism. The dependence of the number of modification of rounding (Fig. 2, b). Not only CAE
ram double pass 𝑛𝑑𝑝 on the vertical spindle rotation developers but also creators of CAD/CAM systems
frequency nsp is determined by the formula: based on the C3D Modeler geometrical kernel will
according to which one double stroke of the ram appreciate the presence of this operation.
corresponds to a value equal to 2.51 spindle
revolutions. 3.3. Rack bar parametric modeling in the
module ARM Graph
3.2. Construction of 3D models of the slotting Profile and dimensions of a rack bar are defined
spindle head by a basic contour (BC) following with GOST
To analyze the effectiveness of the design and to (Standard) 13755-2015 [25]. The BC dimensions
select the optimal variant of the slotting head (SH) predetermine the dimensions of the rack teeth: the
design of a CNC multioperational machine tool thickness of the teeth Sn; the height of the dividing
model SF68VF4 [21, 22], a 3D model has been head Ha; the height of the tooth h, etc.
created in the CAD environment KOMPAS-3D (Fig. To ensure smooth mating of teeth during an
1). In the system outline, there is a set of software, engagement, the basic contour with the modified
including applications for building 3D models for a profile of the tooth head is used. In the process of
variety of shafts and mechanical gears. The teeth cutting the cut flank of the tooth profile near
development of a rather complex SH design is based the addendum circle of the wheel is formed.
on the capabilities of the C3D Modeler geometric
kernel [18]. The C3D modeler is designed to build

a b
Fig. 1. 3D models of the main movement drive for the multi-purpose machine: a – kinematics; b – design

a b c d
Fig. 2. Solid models of the slotting head: a – general view; b – cross-section c – gear rack; d – gear wheel
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Standard 13755-81 regulates the values of The APM FEM module is based on its geometric
modification parameters – height coefficient ℎ𝑔∗ (not kernel. The system includes built-in finite element
more than 0,45) and depth coefficient Δ*. mesh generators with an automatic procedure for
For more productive construction of BC rack bar generating 4-node tetrahedron finite elements. A
and gear cutting tool it is advisable to use the built-in finite element mesh generator has an
parameterization apparatus in the environment of automatic "enhancer" which ensures that
APM Graph module [26, 27]. Parametric models of predominantly equilateral triangles are used as finite
BC rack bar were built in this module (Fig. 3, a and elements, which are optimal in terms of minimizing
Fig. 3, b). With a minimum number of initial the error of stress-strain calculations.
parameters of the cut gear (variable window), all The module uses an algorithm for partitioning into
derived data in the command window are defined. volume elements in the mode of auto-selecting the
The creation of the forming closed contour of the maximum length of the element side, the maximum
prismatic rack bar will be considered in the example concentration coefficient and the rarefaction
of the slotting head for the machine model SF68VF4 coefficient in the volume;
(Fig. 1). The initial data are: module m = 1mm; the Let us consider the sequence of procedures of
normal basic contour according to Standard 13755- strength level analysis implementation of the rack bar
81; accuracy degree according to Standard 10242-81- in the APM FEM module. At the initial stage, the
9-B; tooth thickness Sn0 = 1,387- 0,120 mm; measuring fastening and the main types of loadings applied
height ha0 = 0,748 mm; number of teeth z = 21. directly to the elements of the three-dimensional
In the module APM Graph the creation of the model are set, and then the model is partitioned into
parametric model of the rack bar is carried out by finite elements (Fig. 4, a).
using 3D operations: At the stage of complex strength analysis,
- creating the generatrix contour of the tooth surface conducted in the APM FEM module, determination
under the above initial data (Fig. 3, c); of the geometric parameters of the structure, which
- pulling out the generatrix contour of the rack provide the required safety factors, is implemented
prismatic rod in both directions to obtain a model for the given external and internal impacts. The fields
of the rack base (Fig. 3, d). of equivalent stresses in Fig. 4, b, (calculated
- pulling of generatrix contour of teeth profile with following the Mises hypothesis – energy theory of
basic contour according to Standard 13755-81 to strength) in the cross-sections of the rack tooth allow
obtain a solid model of rack tooth profile (Fig. 4, us to conclude about the permissible level of plastic
d). deformation [24, 29, 30]. Similarly, we can conclude
The efficiency of the considered procedure is about the level of principal stresses (only normal
connected with the use of specialized graphic stresses acting on the faces of elementary cross-
primitives of generatrix contours, systematized in sections), presented in Fig. 4, c.
the corresponding database of parametric data of the In the complex stress state, the highest bending
system. stresses are formed at the tooth root in the zone of
transition of the generatrix of the main rack profile
3.4. Estimation of the stress-strain state level of into the transition curve. The stress concentration in
the rack bar this zone can be reduced by increasing the radius of
The application of calculation formulas [4] does curvature of transition curve ρf (if it does not violate
not give a complete picture of the stress-strain state of the correctness of engagement in the transmission)
the rack-and-pinion engagement. To obtain such [31]. The second way to reduce the concentration is
estimates, we will use the numerical finite element to modify the tooth head profile of the basic contour
method (FEM) in the APM FEM module of solid and (if the part value the of the end overlapping
surface modeling integrated into the KOMPAS-3D coefficient, defined by sections of the main profiles
system [22, 24]. This method can sufficiently εaM, will appear less than εaM = 1.1 at spur gearings
describe both the geometry of the structure and the and less than εaM = 1.0 at helical gearings).
nature of the loadings applied to it and the material
properties of the structure [28].
Pno Pno
Sno
20 о Sno
rao
hao

rao
hfo hao
ho

ho

rfo
rfo
m

20 о af

a b

c d
Fig. 3. Construction of the rack bar parametric model in the module ARM Graph: a – normalized BC;
b – modified BC; c – 2D generatrix contour; d – pulling out the generatrix contour
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a b

c d
Fig. 4. Results of strength calculation of rack: a – finite-element mesh; b – equivalent stress (σemax = 14.56 MPa);
c – principal stress field (σpmax = 10.51 MPa); d – displacement field (ymax =0.105 mm)

The field of deformations, presented in Fig. 4, d transition from the rack coordinate system 𝑆1 to the
allows to concluding about insignificant in magnitude coordinate system 𝑆2 {𝑋2 , 𝑌2 , 𝑍2 }, associated with the
displacements in separate sections of the tooth (the rotating pinion: 𝑆1 → 𝑆01 → 𝑆02 → 𝑆2 (Fig. 5) using
displacements shown on the field of deformations are the matrix method of coordinate transformation, we
proportional to real ones), numerical values of which obtain [12, 13]:
are presented on a digital scale.
𝑐𝑜𝑠 𝜑2 − 𝑠𝑖𝑛 𝜑2 0𝑟2 ⋅ (𝜑2 ⋅ 𝑐𝑜𝑠 𝜑2 +
4. RESULTS AND DISCUSSION + 𝑠𝑖𝑛𝑐𝑜𝑠 𝜑2 )
| |
𝑠𝑖𝑛 𝜑2 𝑠𝑖𝑛 𝜑2 0𝑟2 ⋅ (𝜑2 ⋅ 𝑠𝑖𝑛 𝜑2 −
𝑟⃗2 = ⋅ 𝑟⃗1 .
4.1. Theoretical part | − 𝑐𝑜𝑠 𝜑2 ) |
As shown above, the issue of reducing the level of 0001
stress and improving the service life of the gear 0001
transmission through structural modification is an (3)
urgent task. In the parametric form [33], dependence (3) will
In this paper, a structural variation of the rack- appear as:
and-pinion transmission with increased load capacity 𝑋2 = (0.33 ⋅ 𝑚 + 𝑢 ⋅ 𝑠𝑖𝑛 𝛼 + 𝑟2 ⋅ 𝜑2 ) ⋅ 𝑐𝑜𝑠 𝜑2 −
is proposed, which is supported by the previously −[𝑟𝑚𝑐 ⋅ (1 − 𝑐𝑜𝑠 𝑣) + 𝑢 ⋅ 𝑐𝑜𝑠 𝛼 ⋅ 𝑐𝑜𝑠 𝑣 −
obtained patent solution [32]. −𝑚 ⋅ (0.5 ⋅ 𝑧 + 1.25] ⋅ 𝑠𝑖𝑛 𝜑2 ;
As is known, the most common method of cutting 𝑌2 = [𝑟𝑚𝑐 ⋅ (1 − 𝑐𝑜𝑠 𝑣) + 𝑢 ⋅ 𝑐𝑜𝑠 𝛼 ⋅ 𝑐𝑜𝑠 𝑣 −
the rack teeth (Fig. 2) is carried out by copying with −𝑚 ⋅ (0.5 ⋅ 𝑧 + 1.25] ⋅ 𝑐𝑜𝑠 𝜑2 +
a disk cutter with rectilinear cutting edges. As a result, +(0.33 ⋅ 𝑚 + 𝑢 ⋅ 𝑠𝑖𝑛 𝛼 + 𝑟2 ⋅ 𝜑2 ) ⋅ 𝑠𝑖𝑛 𝜑2 ;
the surface of the rack teeth is formed, which in the {𝑍2 = (𝑟𝑚𝑐 − 𝑢 ⋅ 𝑐𝑜𝑠 𝛼) ⋅ 𝑠𝑖𝑛 𝑣 .
coordinate system 𝑆1 {𝑋1 , 𝑌1 , 𝑍1 } rigidly connected (4)
with the rack bar, is described by the equation: Limits of change in the independent variables:
𝑟⃗1 = (0.33 ⋅ 𝑚 + 𝑢 ⋅ 𝑠𝑖𝑛 𝛼) ⋅ 𝑖⃗1 + 𝑢 = [0; 2.25 ⋅ 𝑚/ 𝑐𝑜𝑠 𝛼];
+[𝑟𝑚𝑐 − 1.25 ⋅ 𝑚 − (𝑟𝑚𝑐 − 𝑢 ⋅ 𝑐𝑜𝑠 𝛼) ⋅ 𝑐𝑜𝑠 𝑣] × 𝑣 = 𝑎𝑟𝑐𝑠𝑖𝑛 (
±0.5⋅𝑏𝑊
).(5)
⃗⃗1 , 𝑟𝑚𝑐 −𝑢⋅𝑐𝑜𝑠 𝛼
× 𝑗⃗1 + (𝑟𝑚𝑐 − 𝑢 ⋅ 𝑐𝑜𝑠 𝛼) ⋅ 𝑠𝑖𝑛 𝑣 ⋅ 𝑘 (1)
The limits of variation of these variables are
where [𝑢, 𝑣] – the independent variables defining
determined from the following conditions [30]. The
the coordinates of a point on the rack tooth surface;
linear parameter defines the moving of a point on a
𝑚 – the rack transmission module; 𝑟𝑚𝑐 – the nominal
profile of the cutter from its top (𝑢 = 𝑢𝑚𝑖𝑛 to a root
radius of the milling cutter; 𝛼 = 200 – the angle of
of a rack tooth in height ℎ = 2.25 ⋅ 𝑚 given a slope
the cutting edges on the milling cutter.
of cutting edges 𝛼 = 200 (𝑢 = 𝑢 𝑐𝑜𝑠 𝛼𝑚𝑎𝑥 . The
The axial profile of the rack teeth is defined by the
angular parameter 𝑣 is found from the condition that
system of equations:
the coordinate 𝑍2 is limited by the width of the tooth ring
𝑋1 = 0.33 ⋅ 𝑚 + 𝑢 ⋅ 𝑠𝑖𝑛 𝛼 ;
pinion 𝑏𝑊 , that is, 𝑍2 = [− 0.5 ⋅ 𝑏𝑊 ; +0.5 ⋅ 𝑏𝑊 ].
𝑌1 = 𝑟𝑚𝑐 − 1.25 ⋅ 𝑚 − (𝑟𝑚𝑐 − 𝑢 ⋅ 𝑐𝑜𝑠 𝛼) ⋅ 𝑐𝑜𝑠 𝑣 ;
± 0.5⋅𝑏𝑊 Equations (4) describe the family of tooth surfaces
𝑣 = 𝑎𝑟𝑐𝑠𝑖𝑛 ( ),(2) of the rack in its motion relative to the pinion axis –
𝑟𝑚𝑐 −𝑢⋅𝑐𝑜𝑠 𝛼
where 𝑏𝑊 – width of the tooth ring pinion. The point 𝑂2 . To obtain their enveloping surface, that is,
definition of the parameter is given below. the surface of the rotating pinion teeth in a coordinate
The pinion tooth surface is the envelope of the rack system rigidly connected with it, let us compose the
tooth surface in relative motion. By successive equation of engagement 𝐹(𝑢, 𝑣, 𝜑2 ) = 0 "rack ↔
pinion", using the kinematic method:
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Krol O, Sokolov V, Golubenko A.: Modification of rack-and-pinion transmission design with …

a b
Fig. 5. Cutting of rack teeth: a – cutting scheme; b – the transition of a coordinate system

⃗⃗1(12) = 0,
𝑛⃗⃗1 ⋅ 𝑉 (6) The nominal diameter of the milling cutter [30] is
⃗⃗ chosen taking into account the following constraint:
where 𝑛⃗⃗1 = 𝑛𝑋1 ⋅ 𝑖⃗1 + 𝑛𝑌1 ⋅ 𝑗⃗1 + 𝑛𝑍1 ⋅ 𝑘1 –
𝑟𝑂 > 0.5 ⋅ 𝑏𝑊 , Fig. 7. By introducing a safety factor
normal vector to tooth surface of the rack; 𝑉 ⃗⃗1(12) =
𝑘 > 1, this constraint can be represented in the form
⃗⃗1(1) − 𝑉
𝑉 ⃗⃗1(2) – vector of relative velocity. of equality:
Omitting substitution of values 𝑛⃗⃗1 and 𝑉 ⃗⃗1(12) , and 𝑟𝑂 = 0.5 ⋅ 𝑘 ⋅ 𝑏𝑊 . (9)
further transformations, let us write equation (6) in The radii 𝑟𝑚𝑐 and 𝑟𝑂 are connected by the tooth
expanded form: height ℎ = 2.25 ⋅ 𝑚, Fig. 7, therefore:
𝑟𝑚𝑐 − (𝑟𝑚𝑐 − 𝑢 ⋅ 𝑐𝑜𝑠 𝛼) ⋅ 𝑐𝑜𝑠 𝑣 − 1.25 ⋅ 𝑚 + 𝑟𝑂 = 𝑟𝑚𝑐 − 2,25 ⋅ 𝑚. (10)
(𝑟 ⋅ 𝜑2 + 0.35 ⋅ 𝑚 + 𝑢 ⋅ 𝑠𝑖𝑛 𝛼) ⋅ 𝑠𝑖𝑛 𝛼 = 0, (7)
where 𝑟 = 0.5 ⋅ 𝑚 ⋅ 𝑧 – the pitch radius of the
rack; 𝑧 – the number of the rack teeth.
Hence express the third variable – 𝜑2 , through
other two – [𝑢, 𝑣], that is, find 𝜑2 = 𝜑2 (𝑢, 𝑣):
−[𝑟𝑚𝑐 −(𝑟𝑚𝑐 −𝑢⋅𝑐𝑜𝑠 𝛼)⋅𝑐𝑜𝑠 𝑣−
−1.25⋅𝑚]−(0.35⋅𝑚+𝑢⋅𝑠𝑖𝑛 𝛼)⋅𝑠𝑖𝑛 𝛼
𝜑2 = . (8)
𝑟⋅𝑠𝑖𝑛 𝛼
The joint consideration of (4) and (8) is the
equation of the enveloping surface 𝑟⃗2 = 𝑟⃗2 (𝑢, 𝑣), that
is, the equation of the pinion teeth surface.
Based on the proposed procedure for the Fig. 7. To calculate the nominal diameter of
development of a modified rack-and-pinion the milling cutter
transmission in the CAD environment is created its
three-dimensional model (Fig. 6). Since the left parts of equations (9) and (10) are
equal, we equate their right parts. As a result, the
minimum possible value 𝑟𝑚𝑐 = 𝑟𝑚𝑐(𝑚𝑖𝑛()) for the
specified value 𝑘:
𝑟𝑚𝑐(𝑚𝑖𝑛) = 0.5 ⋅ 𝑘 ⋅ 𝑏𝑊 + 2.25 ⋅ 𝑚 (11)
It is finally assumed that 𝑟𝑚𝑐 ≥ 𝑟𝑚𝑐(𝑚𝑖𝑛()) .
For a transmission with parameters 𝑚 = 4𝑚𝑚; 𝑏𝑊 =
85𝑚𝑚 at 𝑘 = 1.2: 𝑟𝑚𝑐(𝑚𝑖𝑛) = 0.5 ⋅ 1.2 ⋅ 85 + 2.25 ⋅
4 = 56𝑚𝑚.
It is possible to recommend 𝑘 ≈ 1.2. . .1.4.
The bending strength of the teeth in the proposed
version of the rack-and-pinion transmission will be
higher than in the conventional transmission. This is
explained by the fact that with the same pinion width
𝑏𝑊 , the length of the teeth in the rack transmission
Fig. 6. Three-dimensional model of the with curved axoids, 𝐿𝑂 =∪ 𝐶1 𝐶2 (Fig. 6) will be
modified rack-and-pinion transmission greater than in the transmission in normative form
[30], where tooth length 𝐿𝑊 and width 𝑏𝑊 coincide:
4.2. Experimental part
𝐿𝑊 = 𝑏𝑊 . The ratio 𝐿𝑂 /𝐿𝑊 is mainly responsible for
To build the face profile of the pinion teeth it is
the amount of bending stress reduction in the teeth of
sufficient to calculate the coordinates 𝑋2 and 𝑌2 , using
the proposed rack transmission in comparison with
the system of equations (4), (2,c) and (8).
the transmission [30]:
 DIAGNOSTYKA, Vol. 23, No. 1 (2022) 7
Krol O, Sokolov V, Golubenko A.: Modification of rack-and-pinion transmission design with …
𝑟𝑂 ⋅𝛾
𝐿𝑂 /𝐿𝑊 = = Writing the article, O.K., V.S., A.G.; Critical revision of the
𝑏𝑤 article, O.K., V.S., A.G.; Final approval of the article, O.K.,
𝑟𝑚𝑐 −2.25⋅𝑚 0.5⋅𝑏𝑊
=2⋅ ⋅ 𝑎𝑟𝑐𝑠𝑖𝑛 ( ). (12) V.S., A.G.
𝑏𝑊 𝑟𝑚𝑐 −2.25⋅𝑚
For a transmission with the parameters given Declaration of competing interest: The authors declare
above, at 𝑟𝑚𝑐 = 70𝑚𝑚 > 𝑟𝑚𝑐(𝑚𝑖𝑛) = 56𝑚𝑚 (which that they have no known competing financial interests or
corresponds to 𝑘 = 1.25), the ratio 𝐿𝑂 /𝐿𝑊 : personal relationships that could have appeared to
70−2.25⋅4 influence the work reported in this paper.
𝐿𝑂 /𝐿𝑊 = 2 ⋅ ×
85
0.5⋅85
× 𝑎𝑟𝑐𝑠𝑖𝑛 ( ) ≈ 1.11, (13) REFERENCES
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