mIntroduction

mGear types
mGear Assemblies
mVelocity ratio
mGear manufacturing
mGearbox
Gears are the most common means used for power transmission.

They can be applied between two shafts which are:

mMarallel
m Merpendicular and intersecting
m Merpendicular and non-intersecting
Gears are made to high precision.

 However it is necessary to design for a specific application so that

proper selection can be made.

 Used to be called toothed wheels dating back to 2600 b.c.

u.Spur gears.
2.Helical gears.
3.Herringbone Gears.
4.Bevel Gears.
5.Worm gears.
6.Rack and pinion.
½ost common form.
 Used for parallel shafts.
 Suitable for low to medium speed
application.
 Relatively high ratios can be
achieved (< 7).
 Steel, brass, bronze, cast iron, and
plastics.
 Can also be made from sheet metal.
Internal spur gear
 Mrovides more compact drives compared to external gears
 They provide large contact ratio
 Relatively less sliding and hence less wear compare to external gears
Used for parallel shafts.
 Teeth engage gradually reducing shocks.
Teeth are at an angle ƹ.
Helix angle 7 to 35 degrees.
 Helix angle must be the same for
both the mating gears.
Used in automobiles.
 ½ore smooth and quiet operation.
 ½ore power.
 Larger speeds.
Mroduces axial thrust which is a
disadvantage.
A herringbone gear, also known
as a double helical gear.
To avoid axial thrust, two
helical gears of opposite hand can
be mounted side by side, to cancel
resulting thrust forces
Herringbone gears are mostly
used on heavy machinery.
They have conical shape.
Bevel gears are useful when the direction of a shaft's rotation
needs to be changed .
They are usually mounted on shafts that are 90 degrees apart, but
can be designed to work at other angles as well.
The teeth on bevel gears
can be straight, spiral or
hypoid.

locomotives, marine
applications, automobiles,
printing presses, cooling
towers, power plants, steel
plants, railway track
inspection machines, etc.
Straight bevel gears Spiral bevel gears

Hypoid bevel gears

èor large speed reductions between two perpendicular and non-
intersecting shafts.
 Driver called worm looks like a thread.
½any worm gears have an
interesting property that no other
gear set has: the worm can easily
turn the gear, but the gear cannot
turn the worm
 Worm gears are used widely in
material handling and
transportation machinery, machine
tools, automobiles etc
Rack and pinion gears are
used to convert rotation
(èrom the pinion) into linear
motion (of the rack)

A perfect example of this

is the steering system on
many cars
mIdentified based on the input and output shaft positions:

M
  M

 
  
 

R
  
   


  
Velocity ratio is defined as the ratio of rotational speed of the input gear
to that of the output gear

Õ
i   [
u Õu
§ i = Velocity ratio or reduction ratio
§ Nu = Number of teeth on pinion
§ N2= Number of teeth on gear
§ du = Mitch diameter of pinion
§ d2 = Mitch diameter of gear
½ethods of ½anufacturing Gears

èorming the gear teeth by using milling

Generating the gear teeth by gear shaping
Generating the gear teeth by gear hobbing
GEAR ½ILLING
GEAR SHAMING GEAR HOBBING
A transmission or gearbox provides speed and
torque conversions from a rotating power source to
another device using gear ratios.
Basic types of gearboxes:
Marallel shaft gearbox.
Mlanetary gearbox.
½anufactured from either cast iron or aluminium, the casing must be strong to
withstand the lateral forces generated, as power flows between gear clusters

The transmission housing must be able to support and secure the various
shafts and components in the transmission system. Mrecision bores, faces and
grooves are used to house the bearings &washers.
Because manual transmissions operate at high speeds, gears can easily
overheat. Lubrication is needed to ensure smooth and durable operation.

 

 è



 








The transmission casing, contains the lubrication required for the gearing.
A filler plug in the side and a drain plug underneath, enable the oil to be
topped up and changed.
The input shaft, also known as the clutch shaft, has a
splined end that is directly connected to the clutch plate.
R
Clutch rotation is directly transferred to the input shaft. 




R

The input shaft is supported by a bearing
fitted to a shoulder and pressed into the
transmission casing.

A single gear is used to drive the counter shaft. Cone and 



synchronizer teeth may be incorporated for engaging the
output shaft to the input shaft. 
 6

 












The counter shaft gear consists of a cluster of various gears, all rotating at the same speed,
and continuously meshed with the gears on the input and output shafts.
The counter shaft always turns in the opposite direction from the input shaft. It often runs
the length of the transmission case and uses thrust washers to limit sideways motion of the
gear.
When selecting reverse, the
direction of drive is changed. This is 6
 


achieved by using an idler gear. 

The idler gear is meshed

between a counter shaft
gear and an output shaft
gear.
 

  
Construction is generally a 
  !"
  
gear on a fixed shaft, 

which is supported by
bushes or roller/needle
bearings.
The output shaft, also called the main shaft, is connected to the drive shaft.
Casing supports, used in conjunction with bearings, hold the shaft in place.
Different sized gears are mounted on the output shaft.
These gears rotate freely on the output shaft, and are meshed with the gears
of the counter shaft.
Smooth and precise gear selection is carried out using synchronizers. These
prevent the clashing or crunching of gears.
Each synchronizer is normally used to select one of two different gears.
The synchronizers are held in place by splines on the output shaft, so they
rotate with the shaft.
 $%#

$
&
 

#

 
('


( $
&
  



 

'
Selector forks are used to move the

synchronizer sleeves into the
required positions. The number of
forks varies with the number of
gears.



 
The selector forks are moved by
selector rods (rails). The driver·s gear
lever controls the selector rods.
When the driver selects a lever
position, this transfers the
movement to the selector forks,
which in turn move the
synchronizer sleeves.

') $*
 R
 
+   R


è

R
 

There are two main types of linkages: external and internal. These connect the driver·s gear
lever to the selector rods and forks.
Various configurations of linkage are used depending on the position of the transmission in
relation to the lever (for example, rear wheel drive or front wheel drive vehicles).
The diagram above shows a single rail selector that uses one selector rod. The rod has fixed pins
to move the selector forks. The gate is formed by extensions of the selector forks. To select a
gear, the rail is rotated until the selector pin aligns with the required selector fork and then
moved backwards or forwards.
'* $*
½ulti-rail selection uses selector rods sliding in
R
the gearbox housing. Sliding with these rods are
 
the selector forks, which fit onto the synchronizer
sleeves.
R


Mushing a selector fork will move the outer
sleeve of the synchronizer hub to engage
the selected gear.

he lower end of the gear lever

moves between the three selector
gates to align with one rod.
hen the gear lever is moved
forward or backward, the
selector rod and fork move R
 R

laterally.   
', $*



6
 




 

 .
.



  . .


. /
'- $*
u

6
 



 




#
/
(0 $*
î


6
 



 




$
/
(# $*
6


6
 



 




'
/
($ $*
{

6
 



 



(

/
.   #1#"/
(' $*
J

6
 



 




2
.   /
(( $*
x


6
 



 



 


.

/
(2 $*
Thank you