Gear Force Analysis

UNIT 14 GEAR FORCE ANALYSIS

Structure
14.1 Introduction
Objectives

14.2 Force Analysis in Spur Gears

14.3 Force Analysis in Helical Gears
14.4 Force Analysis in Worm Gears
14.5 Force Analysis in Bevel Gears
14.6 Summary
14.7 Key Words
14.8 Answers to SAQs

14.1 INTRODUCTION
In the last unit static analysis and dynamic analysis was explained. The free body
diagrams of different links of mechanism were drawn. The equilibrium equations or force
polygon can easily be drawn by using free body diagram to determine desired force.
These principles of force analysis can be suitably extended for an analysis of gear forces.
For spur gear analysis is made in two dimensions but in case of helical, spiral, worn and
bevel gears, the for analysis is to be made in three dimensions. In this unit, the gear force
analysis for different type of gears has been briefly discussed.

Objectives
After studying this unit, you should be able to
• do force analysis for spur gears,
• explain force analysis for spiral gears, and
• describe force analysis for bevel gears.

14.2 FORCE ANALYSIS IN SPUR GEARS

The teeth in the spur gears are aligned parallel to the gear axis. Let us consider a simple
gear train consisting only two gears as shown in Figure 14.1(a). The gears are
represented by the pitch circles of gears. The power is transmitted from pinion 2 to
gear 3. Torque acting on pinion 2 is T2 and speed is N2. The sense of T2 and N2 are shown
in the figure. The speed of gear 3 is N3. Since the pinion is the driver, therefore, the sense
of torque and speed shall be the same.
Figure 14.1(b) shows the free body diagrams of pinion and gear. Both pinion and gear
each are subjected to two forces. These two forces should be parallel and equal is
magnitude. The couple generated by these two forces should be equal to the torque
applied on the pinion in magnitude but opposite in action.
The tooth load on the pinion and gear are F32 and F23, respectively. These forces are also
equal in magnitude but opposite in direction. The line of action of these forces shall be
along the common normal which is inclined to the common tangent to the pitch circles by
the pressure angle ‘φ’. The gear is driven by the pinion. The gear is subjected to the load
torque T3. The reaction at the hinge of the gear shall be equal in magnitude to the tooth
load but opposite in direction. The couple generated by these two forces shall be equal to
the load torque T3 on gear 3.
21

F13
F13
B B

O B B
Static and Dynamic
Force Analysis and
Mechanical Vibration

(a) (b)
Figure 14.1 : Simple Spur Gear Train

The tooth load on the pinion can be resolved along the radial and tangential directions as
shown in Figure 14.2.
F32

r
F32
θ
t
F32

t
F12 O2
φ
r
F12 N2 T2
F12

Figure 14.2 : Components of Tooth Load

The tangential component
t
F32 = F32 cos φ
and, radial component
F32r = F32 sin φ
In practice, power at the driving gear is known. With the help of given speed, torque ‘T2’
on the gear can be determined. From the teeth and module pitch circle radius can be
determined, i.e.
t2 , m
r2 =
2
where ‘t2’ and ‘m’ are number of teeth and module, respectively.
With the help of torque ‘T2’ tangential component of tooth load can be determined.
T2
t
F32 = . . . (14.1)
r2

22
 Gear Force Analysis
Ft
∴ F32 = 32 . . . (14.2)
cos φ

and F32r = F32

t
tan φ . . . (14.3)
Similarly, the reaction force at the hinge can be determined.

F12t = − F32
t
and F12r = − F32r

SAQ 1
Which one of these two, i.e. normal tooth and tangential component is determined
earlier?

14.3 FORCE ANALYSIS IN HELICAL GEARS

A helical gear may be left handed or right handed. Figure 14.3(a) shows a left handed
helical gear. It can be a driver or driven gear. Let us assume that it is a driver gear. The
normal force on the tooth F32 can be resulted in three components namely tangential,
radial and axial. This can be assumed to be acting along the diagonal of a parallalopiped.
The parallelopiped is shown by dotted lines with one corner at the pitch point. It is shown
enlarged in Figure 14.3(b). The normal reaction on the tooth F32 has been shown along
the diagonal EP. The angle EPF is equal to the pressure angle ‘φ’ and ∠ GPF in the
t
horizontal plane will be equal to the helix angle ‘ψ’. The components F32 , F32r and F32a
shall be along the lines GP, CP and AP, respectively. Firstly force ‘F32’ can be resolved
in the vertical plane passing through the lines FP and CP.
r
F32

D C

a r
F32 F32 F32
t
F33 t
F32
O2 G
F32 P
φ a
B F32
E
ψ
T2

F A

(a) (b)

Figure 14.3 : Helical Gear Forces

Therefore, the radial component

F32r = F32 sin φ . . . (14.4)

where φ is normal helix angle.

and F32FP = F32 cos φ 23

Static and Dynamic ∠ GPF = Helix angle ' ψ '
Force Analysis and
Mechanical Vibration Therefore, the tangential component is given by
t
F32 = F32FP cos ψ = F32 cos φ cos ψ . . . (14.5)
The axial component is given by

F32a = F32FP sin ψ = F32 cos φ sin ψ . . . (14.6)

As discussed in the last section, the tangential component can be calculated from driving
torque and tooth load can be determined from it. Therefore,
t
F32
F32 = . . . (14.7)
cos φ cos ψ
t
F32
∴ F32r = sin φ = F32
t
tan φ sec ψ . . . (14.8)
(cos φ cos ψ)

and F32a = F32

t
tan ψ . . . (14.9)
The direction of these components can be determined as follows :

(a) The direction of the radial component F32r or F23

r
is always towards the gear
centre.
(b) The direction of the tangential component is tangent to the pitch circle and
opposite to the sense of rotation for driving gear and in the sense of rotation
of the driven gear.
(c) The direction of the axial component of the normal tooth load is in the
direction of advancement of the screw having the same hand as the helix
when it is rotated in the direction of rotation of the driving gear. The thrust
on the driven gear is equal and opposite to that acing on the driver. It has
been clearly shown in Figures 14.4(a), (b), (c) and (d).
Driver Driven Driver Driven

RH RH LH LH

Thrust Thrust Thrust Thrust

Thrust Thrust Thrust Thrust

RH
LH LH RH
Driven Driver Driven Driver

(a) (b) (c) (d)

Figure 14.4 : Direction of Axial Thrust

SAQ 2
Why should there be three components in case of helical gear instead of two?

24
 Gear Force Analysis
14.4 FORCE ANSLYSIS IN WORM GEARS
In worm and worm gear drive, worm is always the drive because it is a non-reversible
drive. Worm can be right handed or left handed. The different components of normal
tooth load on the worm have been shown in Figures 14.5(a), (b), (c) and (d) for different
sense of rotation and different hands.
Worm Driver LH Worm Driver LH
2
2

a t a
F32 t F32 r F32
r F32 F32
F32
r
t r F23 t
F23 F23 a F23
a F23
F23

3 3

(a) (b)

RH RH
2
2

t a t
F32 a F32 r F32
r F32 F32
F32
r
a r F23 a
F23 F23 t F23
t F23
F23

3 3

(c) (d)
Figure 14.5 : Forces on Worm and Worm Gears

In Figures 14.5(a) and (b) worm is left handed whereas in Figures 14.5(c) and (d) worm
is right handed. For given sense of rotation and hand the direction of components of
normal tooth load is shown in Figure 14.5. The worm has been considered as link 2 and
worm gear is considered as link 3. It may be observed that the tangential component in
work generates a component parallel to the axis of the worm gear. The axial component
in case of worm generated component in tangential direction in worm gear. For worm,
lead angle (λ) is used in place of helix angle which is used for helical or spiral gears.
Lead angle (λ) and helix angle (ψ) are related

ψ = (90o − λ )
The radial component

F32r = F32 sin φ . . . (14.10)

t
F32 = F32 cos φ cos (90o − λ )

or t
F32 = F32 cos φ sin λ . . . (14.11)
25
Static and Dynamic
F32a = F32 cos φ sin (90o − λ )
Force Analysis and
Mechanical Vibration
or F32a = F32 cos φ cos λ . . . (14.12)

Also t
F23 = − F32
t

r
F23 = − F32r

a
F23 = − F32a

and F23 = − F32

It may be observed that the radial component is directed towards the centre. The
tangential component generates axial stress in the shaft of the worm gear. The axial
component generates torque in the worm gear. The tangial component can be determined
for the worm by using given power, speed and pitch circle radius. The normal tooth load
then can be calculated by using tangential component. Other quantities can be determined
afterwards by using normal tooth load.

SAQ 3
What is the relation between load angle and helix angle?

14.5 FORCE ANALYSIS IN BEVEL GEARS

A bevel gear drive is used for intersecting shafts. The gears of a simple bevel gear drive
is shown in Figure 14.6. The two gears of a simple bevel gears are shown separated from
each other. The included cone angle for gear 2 is 2γ2 and for the gear is 2γ3. The normal
tooth load has been shown. This force can be assumed to act at the mean pitch radius of
the pinion. The tangential component shall have the line of action perpendicular to the
plane of the paper and it can be determined with the help of the power, angular speed and
the pitch circle radius of the driver.

F32n = F32
t
tan φ

where φ is the pressure angle.

i.e. F32r = F32n cos γ 2 = F32

t
tan φ cos γ 2

and F32a = F32n sin γ 2 = F32

t
tan φ sin γ 2

where γ2 is the semi-cone angle.

For gear 3
t
F23 = − F32
t

and n
F23 = − F32n
26
 Gear Force Analysis
3
t
F23

Driven

n
F32
γ3
t n
F32 F23

t
γ2 F32
2 t Tangential Component
t
F23 = − F32 coming out of the Paper

Driver

Figure 14.6 : Bevel Gear Forces

t
All these three components namely, F32 , F32r , F32a , F23
t r
, F23 a
and F23 have been shown
acting in Figure 14.7.

t
F23
Driven
a
r F23
F32
γ3
r
a F23
t F32
F32

γ2

Figure 14.7 : Force Component on the Bevel Gear

SAQ 4
What is the utility of semi-cone angle in determining components of tooth load?

Example 14.1
A gear train consists of helical gears the pitch radii of the driver, intermediate and
driven gear are 5 cm, 8 cm and 6 cm, respectively. The normal pressure angle is
20o and a helix angle of 30o. The input torque is 15000 N.
Solution
Given data :
Input torque = 15000 N
Radii r2 = 5 cm, r3 = 8 cm and r4 = 6 cm
15000
Transmitted force Ft32 = = 3000 N
5

F32a = F32
t
tan ψ = 3000 tan 30o = 1732 N
27
Static and Dynamic tan 30o
Force Analysis and F32r = F32
t
tan φ sec ψ = 3000 = 1260.8 N
Mechanical Vibration cos 30o
z z z
4 2 Driver RH
2 3 Idler LH
4 Follower RH
3

(a)

y y
y

z
T3 T4
T2 a z z
F12
t t
F23 F43
r r r
F32 a F43 F34 a
F23 F34 x
x x
O2 r O3 O4
t F23
F32 a
F14
a t
a F43 F34
z F32

(b)
Figure 14.8

Figure 14.8(a) shows the sense of rotation of various gears and head of the threads
Figure 14.8(b) represents pitch circles of the three gears. The various components
are also shown

F32a = − F12a

and F32a = − F23

a

F12r = − F32r = F23

r

t
F32 = 3000 + 3000 = 6000 N
a
F43 = − F23
a

t
F34 = F43
t
= F23
t
= 3000 N

The output torque T4 = 3000 × 6 = 18000 N

Action of axial components at pitch circles gives rise to resistance torque about
Y-axis

T2y = F32a r2 = 1732 × 5 = 8660 N cm

T3y = 1732 × 2 × 8 = 27712 N cm

T4y = 1732 × 6 = 10392 N cm

The effect of these couples about the OY-axis is to turn each shaft end which
results in additional reactions at the bearings in the direction of X-axis.
Example 14.2
A bevel gear train consists of two gears. The pressure angle of the gear pair is 20o.
The torque input to the gear 2 is 8 kN cm. The gear train is shown in Figure 14.9.
Determine forces on the shaft at A and B, the bearings A and C take side thrusts.
28
 Gear Force Analysis
80 100
69

D C z
y y
3 γ3

200

92
γ2

140
150
A
2

80
T2
B
All Dimensions in mm

Figure 14.9

Solution
Torque input ‘Ti’ = 8 kN cm = 8000 N cm
Pitch cone angle for the pinion
⎛ 15 ⎞
⎜ ⎟
γ 2 = tan −1 ⎝ 2⎠
⎛ 20 ⎞
⎜ ⎟
⎝ 2 ⎠

or γ 2 = 36.87o

⎛ 20 ⎞
⎜ ⎟
γ 3 = tan −1 ⎝ 2 ⎠ = 53.13o
⎛ 15 ⎞
⎜ ⎟
⎝ 2⎠
8000
t
F32 = = 1159.4 N
6.9
F32r = F32
t
tan φ cos γ 2 = 1159.4 tan 20o cos 36.87o = 337.59 N

F32a = F32
t
tan φ sin γ 2 = 1159.4 tan 20o sin 36.87o = 253.19 N

F12Ax = F32a = 253.19 N

F32r − F12By − F12Ay = 0

t
F32 + F12Bz − F12Az = 0
Taking moments about the Z-axis at point B

F12Ay × 8 − F32r × 12.8 + F32a × 6.9 = 0

337.59 × 12.8 − 253.19 × 6.9

F12Ay = = 321.8 N
8

F12By = F32r − F32Ay = 337.59 − 321.8 = 15.79 N 29

Static and Dynamic z
Force Analysis and
Mechanical Vibration
69
a
F32 o y
Az
r F12
F32 t
F32

48
Gear 2 Ay
F12
A
Ax
F12
T2

80
By
F12
B

Bz
F12 All Dimensions in mm

Figure 14.10

Taking moments about Y-axis passing through O

F12Az × 4.8 = F32Bz × 12.8

or F12Az = 2.666 F12Bz

∴ 1159.4 + F12Bz − 2.666 F32Bz = 0

1159.4
or F12Bz = = 695.92 N
1.666

∴ F12Az = 2.666 × F12Bz = 2.666 × 695.92 = 1855.3 N

The components at the bearing A and B have been determined. If necessity arises
their resultant also can be determined.
Example 14.3
A pinion of 8 cm pitch diameter drives a 25 cm gear. The pressure angle of the pair
is 20o. Both pinion and gear are mounted mid-way on simply supported shafts.
Make force analysis of the pair if the input torque is 6000 N cm.
Solution
Given data :
PCD of pinion = 8 cm
PCD of gear = 25 cm
Pressure angle = 20o
Input toque = 6000 N cm
Distance between bearings = 20 cm
6000 × 2
t
F22 = = 1500
8

F32r = F32
t
tan φ = 1500 tan 20o = 555.96 N
t
F23 = − F32
t
= 1500 N
r
F23 = − F32r = 555.96 N
30
 25 Gear Force Analysis
Output torque = 1500 × = 18750 N cm
2
A B

C D

(a)

A B
r
F23 t
F23 Z Z
O
γ Ay 2
F12 By
F12 r
Ax t F32
F12 F32

x
O3

Z Z

C D

(b)

Figure 14.11

The shaft is simply supported and

F32r 555.96
F12Ay = F12By = − = = − 277.98 N
2 2
r
F23 = − F32r = 555.96 N

r
F23
F13Cy = F13Dy = − = − 277.98 N
2
t
F32 1500
F12An = F12Bx = − = = − 750 N
2 2
1500
F13Cx = F13Dx = = 750 N
2
Example 14.4
An epicyclic gear train is shown in the Figure 14.12. The input gear 1 rotates at
20 rpm and receives 1000 N cm torque. All the gears have 20o pressure angle. The
teeth on gears 1, 2, 3, 4, 5 and 6 are 60, 35, 35, 20, 45 and 40, respectively.
Determine output torque and bearing reactions. Assume diametral pitch equal to
4 for all gears and take the bearings B and D to be mid-way between gear 2 and the
arm.
31
Static and Dynamic 80 80 50 50 50 80
Force Analysis and
Mechanical Vibration
5

3
6

A 2 E F
B

4
C 1 D

Figure 14.12

Solution
Given data :
Speed of gear 1 = 20 rpm
Input torque at gear 1 = 1000 N cm
Pressure angle φ = 20o
Diametral pitch = 4
Teeth on gears 1, 2, 3, 4, 5 and 6 = 60, 35, 35, 120, 45 and 40
Pitch diameters of gear 1
60
d1 = × 2.54 = 38.1 cm
4
Pitch diameters of gear 2
35
d2 = × 2.54 = 22.23 cm
4
Pitch diameters of gear 4
120
d4 = × 2.54 = 76.2 cm
4
Pitch diameters of gear 5
45
d5 = × 2.54 = 28.575 cm
4
Pitch diameters of gear 6
40
d6 = × 2.54 = 25.4 cm
4
d3 = d 2

1000 × 2
F12t = = 52.49 N
38.1
Torque on gear 2
22.23
Ti = 52.49 = 583.46 N cm
2
32
 This is the input torque on the epicyclic gear train which is from gear 2 to 6. Gear Force Analysis

Rev. of gear 2
20 × 38.1
N2 = = 34.278
22.23
Sl. Operation Rev. of Rev. Rev. of Rev. of
No. Arm of Gears 3 and Gear 6
Gear 5
4
1. Arm is fixed
and gear 4 is 120 45
0 1 = 3.43 (−) 3.43 = − 3.857
given + 1 35 40
rotation
2. Multiply I row 0 x 3.4 x – 3.857 x
by x
3. Add to II row y x+y 3.43 x + y Y – 3.857 x

y = 34.278
and x+ y=0
or x=− y
or x = − 34.278
Speed of gear 6
N 6 = y − 3.857 x
= 34.278 − 3.857 (− 34.278) = 166.49
Since Ti Wi + To Wo = 0

⎛ 34.278 ⎞
⎜ ⎟
⎛W ⎞ ⎝ 2π × 60 ⎠
∴ To = − Ti ⎜ i ⎟ = − 583.46 ×
⎝ Wo ⎠ ⎛ 2π × 166.49 ⎞
⎜ ⎟
⎝ 60 ⎠
= 120.13 N cm
r
F43
t t
F34 F43
t
F21
5
r
F34
4 + +
O3
O5
T2 O2 + O4 t
t F65 r
F32 F65
t
F12
r
F12
t
r 4 F56
F21
t
F21 r
F56 To
+
+ O6
O1

Figure 14.13

For determining holding torque on fixed gear 4

Ti + Th + To = 0
33
Static and Dynamic or 583.46 + Th − 120.13 = 0
Force Analysis and
Mechanical Vibration or Th = − 463.33 N cm

F12r = F12t tan φ = 52.49 tan 20o = 19.1 N

463.33 × 2
t
F34 = = 12.16 N
76.2

F34r = F34
t
tan φ = 12.16 tan 20o = 4.43 N

120.13 × 2
t
F56 = = 9.46 N
25.4

F56r = F56
t
tan 20o = 9.46 tan 20o = 3.44 N
t
F43 = F34
t
= 12.16 N
r
F43 = F34r = 4.43 N

40

40
80
x 50
A
50
HA
F1
VA
F1 γ
52.49
B 12.16 4.43
19.1

9.46 3.44
HB
F1
VB
F1

Figure 14.14
t
F65 = F56
t
= 9.46 N

and r
F65 = F56r = 3.44 N

d 4 d3 76.2 − 22.23
y= − = = 26.985 cm
2 2 2
Considering forces of horizontal plane and referring Figure 14.14

F1HA + F1HB = 52.49 + 12.16 = 55.19 N

Taking moments about B

F1HA × 12 − 52.49 × 4 + 12.16 × 9 − 9.46 × 14 = 0

or F1HA = 232.84 N

∴ F1HB = 55.19 − F1HA = 55.19 − 232.84 = 177.65 N

Now considering vertical force and referring Figure 14.14

F1VA + F1VB = − 19.1 + 4.43 − 3.44 = − 18.11

Taking moments about point B

34
 Gear Force Analysis
F1VA × 12 + 19.1 × 4 + 4.43 × 9 − 3.44 ×14 = 0

or F1VA = − 5.68 N

∴ F1VB = − 18.11 − F1VA

= − 18.11 + 5.68 = − 12.43 N

C 8 cm

HC
F1 4 cm
VC
F1
D
t
F21
r
F21

HD VD
F1 F1
(a)

5 cm

t E
F56 8 cm
r HE
F56 F1
F
VE
F1

HF
F1 VF
F1
(b)
Figure 14.15

Referring to Figure 14.15(a)

t
F21 = F12t = 52.49 N
r
F21 = F12r = 19.1 N
For horizontal components

F1HC + F1HD = − F21

t
= − 52.49
Taking moment of horizontal components about C.
t
F21 × 8 + F1HD × 12 = 0

8
or F1HD = − × 52.49
12

or F1HD = − 35 N

∴ F1HC = − 52.49 − F1HD = 52.49 + 35 = − 17.49 N

For vertical components

F1VC + F1VD = F21

r
= 19.1
Taking moments about C
35
Static and Dynamic
F1VD × 12 = F2r1 × 8
Force Analysis and
Mechanical Vibration
8
F1VD = 1.91 × = 12.73 N
12

∴ F1VC = 19.1 − F1VD = 19.1 − 12.73 = 7.37 N

Referring to Figure 14.15(b).
For horizontal components

− F1HE + F1HF + F56

t
=0

or F1HE − F1HF = F56

t
= F65
t
= 9.46
Taking moments about E

F1HE × 8 = F56
t
× 5 = 9.46 × 5

5
or F1HE = × 9.46 = 5.91
8

∴ F1HE = 9.46 + F1HF = 9.46 + 5.91 = 15.37 N

For vertical components

F1VE − F1VE − F56r = 0

or F1VE − F1VF = 3.44

Taking moments about E

F1VF × 8 = F56r × 5

5
or F1VF = × 3.44 = 2.15 N
8
∴ F1VE = 3.44 + F1VF = 3.44 + 2.15 = 5.59 N

14.6 SUMMARY
A gear train consists of more than one gear. It is used to transmit power from one shaft to
the other shaft. During transmission of power gear teeth mesh with each other. A pushing
tooth applied tooth load and bears equal and opposite reaction. The normal tooth load is
resolved into two components, viz. tangential and radial for spur gears. Normal tooth
load cannot be determined directly. Only tangential component of tooth load can be
determined directly by dividing torque by pitch circle radius. The normal tooth load can
be determined from tangential component. The radial component can either be
determined with the help of tangential component or normal tooth load.
In case of helical gear, worm and worm wheel and bevel gears there are three
components, viz. tangential, radial and axial. All these forces are ultimately transferred to
the shaft and through gear and then to the supports. Suitable bearings are provided to
resist these forces. These forces also help in designing shafts and gears also.

14.7 KEY WORDS

Tooth Load : It is the force which acts normal to the tooth
profile at the point of contact.

36
Tangential Component of : It is the component of tooth load which tangent to Gear Force Analysis
Tooth Load the pitch circle at pitch point.
Radial Component of : It is the component which is directed towards the
Tooth Load centre of pitch circle.
Axial Component of : It is the normal to the tangential and
Tooth Load components.

14.8 ANSWERS TO SAQs

Refer the preceding text for all the Answers to SAQs.

37