"Each problem that I solved became a rule which

served afterwards to solve other problems."

… Rene Descartes

2
CHAPTER

Gear Trains

Learning Objectives
After reading this chapter, you will know:
1. Classification of Gear Drives, Law of Gearing, Involute Profile
2. Cycloidal Profile, Analysis of Gears, Path of Contact, Arc of Contact, Gear Trains, Flywheels

Introduction
Gears are machine elements that transmit motion by means of successively engaging teeth.
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with another
toothed part to transmit torque, in most cases with teeth on the one gear being of identical shape,
and often also with that shape on the other gear. Two or more gears working in a sequence (train)
are called a gear train or, in many cases, a transmission, such gear arrangements can produce
a mechanical advantage through a gear ratio and thus may be considered a simple machine. Geared
devices can change the speed, torque, and direction of a power source. The most common situation
is for a gear to mesh with another gear, however, a gear can also mesh with a non-rotating toothed
part, called a rack, thereby producing translation instead of rotation.

Gear Classification
Gears may be classified according to the relative position of the axes of revolution. The axes may be

Gears for Connecting Parallel Shafts

1. Spur Gears: They are common types of gears with straight teeth.

2. Helical Gears: The teeth on helical gears are cut at an angle to the face of the gear. Because of the
angle of the teeth on helical gears, they create a thrust load on the gear when they mesh.

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 Gear Trains

3. Double Helical Gears (Herringbone Gears): Herringbone gear is a special type of gear which
is a side to side (not face to face) combination of two helical gears of opposite hands. Their
advantage over the simple helical gear is that the side-thrust of one half is counter-
balanced by that of the other half.

4. Rack and Pinion: Racks are straight gears that are used to convert rotational motion to
translational motion by means of a gear mesh.

Pinion

Rack

Gears for Connecting Intersecting Shafts

Bevel Gears: Bevel gears are useful when the direction of a shaft's rotation needs to be changed. The
teeth on bevel gears can be straight, spiral or hypoid.

Gears for Neither Parallel nor Intersecting Shafts

Worm Gears: Worm gears are used when large gear reductions are needed. It is common for worm
gears to have reductions of 20:1 and even up to 300:1 or greater.

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 Gear Trains

Gear Terminology
Various terms used in the study if gears have been explained below.
Top Land
Face Width Pitch
Addendum Cylinder
Circle Face

Addendum
Space Tooth
Pitch Width Flank
Thick ness Pitch line
Circle
Working Pitch
Depth Pitch Point
Diameter
Bottom Land
Dedendum
Circular pitch
Dedendum
Clearance Pitch
(Root) Circle
Circles
(a) (b)

 Refer figure (a) and (b) shown above

(a) Pitch Cylinders: Pitch cylinders of a pair of gears in mesh are the imaginary friction
cylinders, which by pure rolling together, transmit the same motion as the pair of gears.
(b) Pitch Circle: It is the circle corresponding to a section of the equivalent pitch cylinder by a
plane normal to the wheel axis.
(c) Pitch Diameter: It is the diameter of the pitch cylinder.
(d) Pitch Surface: It is the surface of the pitch cylinder.
(e) Pitch Point: The point of contact of two pitch circles is known as the point.
(f) Line of Centers: A line through the centres of rotation of a pair of mating gears is the line of
centres.
(g) Pinion: It is smaller and usually the driving gear of a pair of mated gears.

 Refer figure shown below

(a) Rack: It is a part of gear wheel of infinite diameter shown in the below figure.
(b) Pitch Line: It is a part of the pitch circle of a rack and is a straight line shown in the below
figure.
Pitch Line

Pressure Angle

Rack

 Pitch is defined as follows

(a) Circular Pitch(p): It is distance measured along the circumference of the pitch circle from a
point on one tooth to the corresponding on the adjacent tooth.
πd
p=
T
Where, p = Circular pitch

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 Gear Trains

d = Pitch diameter
T = Number of teeth
As the expression for p involves π, an intermediate number, p, cannot be expressed
precisely. The angle subtended by the circular pitch at the centre of the pitch circle is
known as the pitch angle (y).

(b) Diametrical Pitch (P): It is the number of teeth per unit length of the pitch circle diameter
in inches
T
P=
d
The limitations of the diametrical pitch are that it is not terms of units of length, but in
terms of teeth per unit length.
Also, it can be seen that
πd T
P= =π
T d
The term diametral pitch is not used in a SI units.

(c) Module (m): It is ratio of the Pitch diameters in mm to the number of teeth. The term is
used is SI units in place of diametrical pitch.
d
m=
T
Also
πd
p= = πm
T
Pitch of two mating gears must be same

(d) Gear Ratio (G): It is ratio of the number of teeth on the gear to that on the pinion
T
G=
t
Where, T = Number of teeth on the gear
t = number of teeth on the pinion

(e) Velocity Ratio (VR): The velocity ratio is defined as the ratio of the angular velocity of the
follower to the angular velocity of the driving gear.
Let
D = Pitch diameter
T = Number of teeth
ω = Angular velocity (rad/s)
N = Angular velocity (rpm)
Subscript 1 = driver
2 = follower
angular velocity of follower
V. R. =
angular velocity of driver
ω2
V. R. =
ω1
N2
= (ω = 2πN)
N1

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 Gear Trains

d1
= (∵ πd1 N1 = πd2 N2 )
d2
T1 πd1 πd2
V. R. = (P = = )
T2 T1 T2

 As per figure (a) & figure (b), the terminology are,

(a) Addendum Circle: It is a circle passing through the tips of teeth
(b) Addendum: It is the radial height of a teeth above the pitch circles. Its standard value is
one module
(c) Dedendum or Root Circle: It is a circle passing through the roots of the teeth
(d) Dedendum: It is the radial depth of a tooth below the pitch circle. Its standard value is
1.157 m.
(e) Clearance: Radial between the addendum and the dedendum of a tooth. Thus,
Addendum circle diameter = d + 2m
Dedendum circle diameter = d − (2 × 1.157 m)
Clearance = (1.157 m – m) = 0.157 m
(f) Full Depth of Teeth: It is the total radial depth of the tooth space
Full depth = Addendum + Dedendum
(g) Working Depth of Teeth: The maximum depth to which a tooth penetrates into the tooth
space of the mating gear is the working depth of teeth
Working depth = sum of addendums of the two gears
(h) Space Width: It is the width of the tooth along the pitch circle
(i) Tooth Thickness: It is the thickness of the tooth measured along the pitch circle
(j) Backlash: It is the difference between the space width and the tooth thickness along the
pitch circle
(k) Face Width: The length of the tooth parallel to the gear axis is the face width.
(l) Top Land: It is the surface of the top of the tooth
(m) Bottom Land: The surface of the bottom of the tooth between the adjacent fillets
(n) Face: Tooth surface between the pitch circle and the top land
(o) Flank: Tooth surface between the pitch circle and the bottom land including fillet.
(p) Fillet: It is the curved portion of the tooth flank at the root circle.

Gear Trains
The combination of gear wheels used to transmit motion for power from one shaft to another shaft
is called a gear train. The gear trains are of the following types

Simple Gear Trains

The typical spur gears as shown in figure. The direction of rotation is reversed from one gear to
another. It has no affect on the gear ratio. The teeth on the gears must all be the same size so if gear
A advances one tooth, so does B and C.
T = Number of teeth on the gear,
D= Pitch circle diameter, N = speed in rpm
D
m = module =
T
and module must be the same for all gears,

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 Gear Trains

V
V
ωA ωB ωC
ωB

Gear A Gear B Gear C

Otherwise they would not mesh

DA DB DC
m = = =
TA TB TC
DA = m TA , DB = m TB and DC = m TC
 = Angular velocity
D
V = Linear velocity on the circle. v=  2 = r
The velocity v of any point on the circle must be the same for all the gears, otherwise they would be
slipping.
DA DB DC
V = A = B = C
2 2 2
A DA = B DB = C DC
A m TA = B m TB = C m TC
Or in terms of rev/min
NA TA = NB TB = NC TC
If A is the driving wheel and C is driven wheel, then
Speed of the driver NA Tc
Velocity Ratio = = =
Speed of the driven NC TA

 Train Value: It is reciprocal of velocity ratio.

In an ideal gear box, the input and output powers are the same so
2π N1 T1 2π N2 T2
P = =
60 60
T2 N1
N1 T1 = N2 T2 ⟹ = = Gear ratio
T1 N2
It follows that if the speed is reduced, the torque is increased and vice versa. In a real gear box,
power is lost through friction and the power output is smaller than the power input. The
efficiency is defined as,
Power out 2π × N2 T2 × 60 N2 T2
η = = =
Power in 2π × N1 T1 × 60 N1 T1
Because the torque in and out is different, a gear box has to be clamped in order to stop the case
or body rotating. A holding torque T3 must be applied to the body through the clamps. The total
torque must add up to zero.

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 Gear Trains

T3
T1

T2

T1 + T2 + T3 = 0
If we use a convention that anti-clockwise is positive and clockwise is negative we can
determine the holding torque. The direction of rotation of the output shaft depends on the
design of the gear box.

Compound Gear Trains

Compound gears are simply a chain of simple gear trains with the input of the second being the
output of the first.
In compound gear train each shaft supports two gear wheels except the first and last
ωB = ωC
ωA TB TP
= × = GR
ωD TC TC
Since ω = 2 × πN
The gear ratio may be
Written as:
Input

B D
Output
A
C

Gear ‘B’

Gear ‘A’ Gear ‘D’

Gear ‘C’

Reverted Gear Train: The driver and driven axes lies on the same line. These are used in speed
reducers, clocks and machine tools.
C
NA TB × TP
GR = =
ND TA × TC
If R and T=Pitch circle radius & number of teeth of the gear
R A + R B = R C + R D and TA + TB = TC + TD

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 Gear Trains

Epicyclic Gear Train

Epicyclic means one gear revolving upon and around another. The design involves planet and sun
gears as one orbit the other like a planet around the sun.
Planet Wheel B

Arm, ‘A’ Arm, ‘A’

C
C
Sun Wheel

The figure shows a gear B on the end of an arm. Gear B meshes with gear C and revolves around it
when the arm is rotated. B is called the planet gear and C is sun wheel.
Suppose gear C is fixed and the arm A makes one revolution. Determine how many revolutions the
planet gear B makes.
Step Action A B C
1 Revolve all once 1 1 1
Revolve C by –1 revolution, keeping TC
2 0 + −1
the arm fixed TB
TC
3 Add 1 1+ 0
TB

Step 1 is to revolve everything once about the center.

Step 2 identify that C should be fixed and rotate it backwards one revolution keeping the arm fixed
as it should only do one revolution in total. Work out the revolutions of B.
Step 3 is simply add them up and we find the total revolutions of C is zero and for the arm is 1.
T
The number of revolutions made by B is 1 + TC Note that if C revolves − 1, then the direction of B is
B
TC
opposite so + TB
.

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 Gear Trains

Solved Examples
Example 1
Two spur gears have a velocity ratio is 1/3. The driven gear has 72 teeth 8 mm
module and rotates at 300 rpm. Calculate the number of teeth and the speed of the driver.
What will be the pitch line velocities?
Solution:
1
T2 = 72, V. R. = , N2 = 300 rpm, m = 8 mm
3
N2 T1 1
(i) V. R. = = =
N1 T2 3
∴ N1 = 900 rpm
T1 1
Also = or T1 = 24
72 3
(ii) Pitch line velocity,
Vp = ω1 r1 or ω2 r2
d1
= 2πN1 ×
2
mT1
= 2πN1 ×
2
8 × 24
= 2π × 900 ×
2
= 542 867 mm/minute
= 9047.8mm⁄s or 9.0478 m/s

Example 2
The number of teeth of a spur gear is 30 and it rotates at 200 rpm. What will be its
circular pitch and the pitch line velocity if it has a module of 2mm?
Solution:
T = 30, m = 2mm, N = 200 rpm, P = πm = π × 2 = 6.28 mm
d mT
Vp = ωr = 2πN × = 2πN ×
2 2
Vp = π × 200 × 2 × 30
Vp = 37699 mm/ min = 628.3 mm/s

Example 3
What is the output in rev/min at D and what is the direction of rotation, if Gear A rotates
in a clockwise direction at 30 revs/min?
Gear A
Gear C

Gear D
Gear B

Gear A-120 Teeth, Gear B- 40 Teeth, Gear C- 80 Teeth, Gear D- 20 Teeth

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 Gear Trains

Solution:
Speed for gear B = 30 × (120/40) = 90 rev/min (CCW)
Since Gear B is at 90rev/min and has the same rotational speed as gear C
Hence, speed of Gear D = 90 × (80/20) = 360 rev/min (CW)

Example 4
In a compound Epicyclic gear train as shown in the fig, has gears A and an annular gears D
& E free to rotate on the axis P. B and C is a compound gear rotate about axis Q. Gear A
rotates at 90 rpm CCW and gear D rotates at 450 rpm CW. Find the speed and direction of
rotation of arm F and gear E. Gears A, B and C are having 18, 45 and 21 teeth respectively.
All gears having same module and pitch.

A P E

B Q Arm, F
C

Solution:
TA = 18, TB = 45, TC = 21, NA = −90rpm, ND = 450rpm:
Since the module and pitch are same for all gears:
The number of Teeth on the Gears is proportional to the pitch circle
∴ rD = rA + rB + rC
⇒ TD = TA + TB + TC
TD = 18 + 45 + 21 = 84 Teeth on Gear D

Gears A and D rotates in the opposite directions

TA TC
∴ Train Value = − ×
TB TD
NL − NArm ND − NF
also T. V. = =
NF − NArm NA − NF
TA TC ND − NF
∴− × =
TB TD NA − NF
18 × 21 450 − NF
− =
45 × 84 −90 − NF
⇒ NF = Speed of Arm = 400.9 rpm (CW)

Now consider Gears A, B and E

rE = rA + 2rB
TE = TA + 2TB

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 Gear Trains

TE = 18 + (2 × 45)
TE = 108 → Number of Teeth on Gear E
Gears A and E rotates in the opposite directions
TA
∴ Train Value = −
TE
NE − NF
also T. V. =
NA − NF
TA NE − NF
∴− =
TE NA − NF
18 NF − 400.9
− =
108 −90 − 400.9
⇒ NE = Speed of gear E = 482.72 rpm(CW)

Example 5
In the train of wheels shown in figure, C gears with A and B, D is on the same axis as C, D
gears with E and F with G. If the arm makes 20 rpm/s. in clockwise direction, and the
wheel A is at rest
G
B
D F
A E

Where, G = 135 Teeth, A = 60 Teeth, B = 120 Teeth, C= 30 Teeth, D = 75 Teeth,

E = 30 Teeth, F = 60 Teeth
Determine:
(i) The speed and direction of rotation of B and G respectively.
(ii) The turning moment of the shaft carrying the wheel G when the arm is turned with a
turning moment of 1.5 kNm.
Solution:
Compound Compound
Conditions
Arm A = 60 C = 30 D = 75 B = 120 E = 30 F = 60 G = 135
Fix the arm A 30 60
−2 × 75 75 5 × −
and give one 60 60 120 −2 × − −2 × − 135
0 +1 − = −2 − = −2 1
30 30 29
revolution to 30 30 =5
=− =5 =−
A 2 9
1 20
Multiply by x 0 x −2x −2x − x 5x 5x − x
2 9
1 20
Add y y x +y −2x + y −2x + y − x+y 5x+y 5x+y − x+y
2 9
Refer table above, when wheel A is at rest: x + y = 0 . . . . (a)
When the arm makes 20 r.p.m in clockwise direction: y = 20 . . . . (b)
From (a) and (b), we have x = −20
(i) The Speed and Direction of Rotation of B and G:

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 Gear Trains

1 1
Speed of wheel B, NB = − x + y = (− × −20) + 20 = 30 rpm (Clockwise)
2 2
20 20
Speed of wheel G, NB = − x + y = (− × −20) + 20
9 9
= 64.44 rpm (Clockwise)
(ii) Turning moment, 𝐓𝐆 :
Tarm × arm = TG × G
Tarm × 2πNarm = TG × 2πNG
Tarm × Narm = TG × NG
1.5 × 20 = TG × 64.44
1.5 × 20
∴ TG = = 0.465 kNm
64.44

Example 6
An Epicyclic gear train consists of a ring gear, three planets, and a fixed sun gear. 11 kW
are transmitted through the input ring gear, which turns clockwise at 1500 rpm. The
diametral pitch is 10 per inch with a 20° pressure angle. The pitch diameters are 127 mm,
63.5 mm, 254 mm for the sun, planets, and ring gear, respectively.
(a) How many teeth are on each gear?
(b) What are the speeds of the sun, ring, and carrier gears?
(c) In what directions do the sun, ring, and carrier gears turn?
(d) What torques are on the input and output shafts?
Solution:
(a) The number of teeth are as follows.
For the sun gear,
1
Nsun = Pd = 10 × × 127
25.4
= 50 Teeth
For the planet gears,
1
Nplanet = Pd = 10 × × 63.5
25.4
= 25 teeth
For the ring gear,
1
Nring = Pd = 10 × × 254
25.4
= 100 teeth
(b) Since the sun gear is fixed, its rotational speed is zero (ωsun = 0).
The rotational speed of the ring gear is ωring = 1500 rev/min.
Since the ring and sun gears rotate in different directions, the train value is negative.
Nring 100
T. V. = − =− = −2
Nsun 50
The rotational speed of the sun gear is
ωsun = (T. V. )ωring + (1 − T. V. )ωcarrier
0 = (−2)(1500) + (1 − (−2))ωcarrier
Solve for the rotational speed of the carrier gear.
(2)(1500)
ωcarrier = = 1000 rev/min
3
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 Gear Trains

(c) From part (b), the direction of rotation of the ring and carrier gears is clockwise. The
sun gear moves in the opposite direction of the ring gear, so the sun gear rotates
counterclockwise.
(d) The torque on the input shaft is
P(9549)
T=
nring
(11)(9549)
= = 70.03 Nm
1500
The torque on the output shaft is
P(9549) (11 )(9549)
T= = = 105.0 Nm
ncarrier 1000
Example 7
4
2 6
5
3
1

An a compound gear train, the pown is transmitted from a motor shaft to output shaft.
The motor shaft is connected to gear 1 whereas the output shaft is connected to gear 6.
The number of teeth on each gear are given as,
T1 = 35, T2 = 80, T3 = 45, T4= 125, T5 = 33, T6 = 75
The motor shaft is rotating at 1126 rpm in the clockwise diredion, find the direction and
speed of output shaft.
Solution:
The gears 1, 3, and 5 are drawing gears whears 2, 4 and 6 are driver gears. The gears 2
and 3 are mounted on the same shaft and hence they rotate in the same direction. The
gear 1 is rotating in clockwise direction, then gear 2 which is in mesh with 1 will rotate is
the anticlockwise direction gear 1 is rotating in clockwise direction, then gear 2 which is
in mesh with 1 will rotate in the anticlockwise direction gear 3 will rotate in the direction
of gear 2. As gear 4 is in mesh with gear 3, will rotate in clockwise direction, gear 5 will
also rotate in clockwise direction as they are rotating an the same shaft. The gear 5 and 6
are in mesh will each other, hence gear 6 will rotate in anticlockwise direction
∴ Direction of output shaft = Anticlockwise.
∴ Speed of the output shaft
Let N6 = Speed of the output shaft.
Speed of first Driver Product of No. of teeth on driver
=
speed of last driver Product of No. of teeth on driver
N1 T2 × T4 × T6 80 × 125 × 75
= = = 14.43
N6 T1 × T3 × T5 35 × 45 × 33
N1 1126
∴ N6 = = = 78 rpm
14.43 14.43

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