Lecture Topic 2.2.1

INSTITUTE OF ENGG.
DEPARTMENT OF AME
Bachelor of Engineering (AME)
Subject Name: Design of Automotive Components
Dr. Akant Kumar Singh
Design of Spur Gears DISCOVER . LEARN .

EMPOWER
Learning Objectives
 To be able to understand tooth profiles, manufacturing of gears
2
Tooth Profile
In actual practice following are the two types of teeth
commonly
1. Cycloidalused:
teeth ; and 2. Involute teeth.
•Cycloidal Teeth
• A cycloid is the curve traced by a point on the circumference of
a circle which rolls without slipping on a fixed straight line.
• When a circle rolls without slipping on the outside of a fixed circle, the
curve traced by a point on the circumference of a circle is known as
epi-cycloid.
• On the other hand, if a circle rolls without slipping on the inside of
a fixed circle, then the curve traced by a point on the circumference of a
circle is called hypo-cycloid.
3
Cycloid
4
EPI-Cycloid
5
HYPO- Cycloid
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7
Involute of a Circle
• An involute of a circle is a plane curve generated by a point on a tangent,
which rolls on the circle without slipping.
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Involute Teeth
• An involute of a circle is a plane curve generated by a point on a tangent, which rolls
on the circle without slipping as shown in Fig.
• In connection with toothed wheels, the circle is known as base circle. The involute is
traced as follows :
Let A be the starting point of the involute. The base circle is divided into
Equal number of parts e.g. AP1, P1P2, P2P3 etc. The tangents at P1, P2, P3 etc.
are drawn and the length P1A1, P2A2, P3A3 equal to the arcs AP1, AP2 and
AP3 are set off. Joining the points A, A1, A2, A3 etc. we obtain the involute
Curve AR. A little consideration will show that at any
Instant A3, the tangent A3T to the involute is perpendicular
to P3A3 and P3A3 is the normal to the involute.
In other words, normal at any point of an involute
is a tangent to the base circle.
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10
Minimum Number of Teeth on the wheel in Order to Avoid
Interference
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Law of Gearing
The common normal at the point of contact between a pair of teeth must always
pass though the pitch point.
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Methods Commonly Used for Gear
Manufacturing
Gears can be manufactured by most of manufacturing processes
discussed so far (casting, forging, extrusion, powder metallurgy). But
as a rule, machining is applied to achieve the final dimensions,
shape and surface finish in the gear. The initial operations that
produce a semi finishing part ready for gear machining as referred to
as blanking operations; the starting product in gear machining is
called a gear blank.
Two principal methods of gear manufacturing included.
1. Gear forming, and
2. Gear generating
Each method includes a number of machining processes, the major
of them included in this section.
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Gear Forming
In gear form cutting, the cutting edge of the cutting tool has a shape
identical with the shape of the space between the gear teeth.
Two machining operations, milling and broaching can be employed to form
cut gear teeth.
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Form
Milling
 In form milling, the cutter called a form cutter travels axially along the
length of the gear tooth at the appropriate depth to produce the gear
tooth. After each tooth is cut, the cutter is withdrawn, the gear blank is
rotated (indexed), and the cutter proceeds to cut another tooth. The
process continues until all teeth are cut.
Each cutter is designed to cut a range of tooth numbers. The precision of
the form-cut tooth profile depends on the accuracy of the cutter and the
machine and its stiffness.
15
16
Broachin
g
Broaching can also be used to produce gear teeth and is particularly
applicable to internal teeth. The process is rapid and produces fine
surface finish with high dimensional accuracy. However, because
broaches are expensive-and a separate broach is required for each size of
gear-this method is suitable mainly for high-quantity production.
17
Gear
Generating
In gear generating, the tooth flanks are obtained (generated) as an
outline of the subsequent positions of the cutter, which resembles in
shape the mating gear in the gear pair.
In gear generating, two machining processes are employed, shaping
and milling. There are several modifications of these processes for
different cutting tool used,
1. Milling with a hob (gear hobbing)
2. Gear shaping with a pinion-shaped cutter, or
3. Gear shaping with a rack-shaped cutter.
Cutters and blanks rotate in a timed relationship: a proportional

feed rate between them is maintained. Gear generating is used for
high production runs and for finishing cuts.
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Gear
Hobbing
Gear hobbing is a machining process in which gear teeth are progressively
generated by a series of cuts with a helical cutting tool (hob).
All motions in hobbing are rotary, and the hob and gear blank rotate
continuously as in two gears meshing until all teeth are cut.
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Commonly Used Gear Materials
Gears can be made of all sorts of materials, including many types of
steel, brass, bronze, cast iron, ductile iron, aluminum, powdered metals,
and plastics.
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Applications of Spur Gears
Spur gears have a wide range of applications. They are used in:
• Metal cutting machines
• Power plants
• Marine engines
• Mechanical clocks and watches
• Fuel pumps
• Washing Machines
• Gear motors and gear pumps
• Rack and pinion mechanisms
• Material handling equipments
• Automobile gear boxes
• Steel mills
• Rolling mills 23
Summary
 Tooth profile – Cycloid, Epi-cycloid, Hypo-cycloid
 Law of Gearing
 Manufacturing of gears
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Quiz
Q 1. Which of the following gear tooth failures is/are induced when maximum Hertz contact
stress on gear tooth surface exceeds surface endurance strength of tooth?
a. Abrasive strength
b. Corrosive wear
c. Destructive pitting
d. Galling
Q 2. The commonly used tooth profiles are
(A) Cycloidal
(B) Involute
(C) Both A & B
(D) None of above
Q 3. The form factor of a spur gear tooth depends upon
a) circular pitch only
b) pressure angle only
c) number of teeth and circular pitch
d) number of teeth and the system of teeth
Answers: 1 – c; 2 – c; 3 - d 25
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References
1. Budynas Richard G. and Nisbett J. Keith, “Shigley’s Mechanical Engineering Design”,
McGraw Hill, 9th edition, 2011
2. Bhandari V, “Design of Machine Elements”, Tata McGraw-Hill Education, 2010
3. Kulkarni S. G, “Machine Design”, Tata McGraw-Hill Education, 2008
4. Jadon V.K. and Verma S., “Machine Design Data Book”, 2 nd edition.
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Learning Outcomes
• Understand the gear tooth profiles, manufacturing of gears
27
THANK YOU
For queries
Email: [email protected]

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INSTITUTE OF ENGG.

Dr. Akant Kumar Singh

Design of Spur Gears DISCOVER . LEARN .

 To be able to understand tooth profiles, manufacturing of gears

Cutters and blanks rotate in a timed relationship: a proportional

• Understand the gear tooth profiles, manufacturing of gears

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