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Gears are the most common form of power transmission for several reasons. They can be scaled to transmit power from small battery powered watch motors (or even microscopic), up to the power from thousand horsepower gas turbine engines. Properly mounted and lubricated, they transmit power efficiently, smoothly, and quietly. They can transmit power between shafts that are parallel, intersecting, or even skew. For all their pluses, there are a few important things to remember about gears. To be efficient and quiet, they require high precision, both in the shape of the teeth and the distance between one gear and its mating gear. They do not tolerate dirt and must be enclosed in a sealed case that keeps the teeth clean and contains the required lubricating oil or grease. In general, gears are an excellent choice for the majority of power transmission applications. Gears come in many forms and standard sizes, both inch and metric. They vary in diameter, tooth size, face width (the width of the gear), and tooth shape. Any two gears with the same tooth size can be used together, allowing very large ratios in a single stage. Large ratios between a single pair of gears cause problems with tooth wear and are usually obtained by using cluster gears to reduce the gearbox s overall size. Figure 2-14 shows an example of a cluster gear. Cluster gears reduce the size of a gearbox by adding an interim stage of gears. They are ubiquitous in practically every gearbox with a gear ratio of more than 5:1, with the exception of planetary and worm gearboxes. Gears are available as spur, internal, helical, double helical (herringbone), bevel, spiral bevel, miter, face, hypoid, rack, straight worm, double enveloping worm, and harmonic. Each type has its own pros and cons, including differences in efficiency, allowable ratios, mating shaft angles, noise, and cost. Figure 2-15 shows the basic tooth profile of a spur gear. Gears are versatile mechanical components capable of performing many different kinds of power transmission or motion control. Examples of these are Changing rotational speed. Changing rotational direction. Changing the angular orientation of rotational motion. Multiplication or division of torque or magnitude of rotation. Converting rotational to linear motion and its reverse. Offsetting or changing the location of rotating motion.
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Figure 2-14 Cluster gear
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Figure 2-15 Gear Tooth Terminology
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Gear Tooth Geometry: This is determined primarily by pitch, depth, and pressure angle.
Gear Terminology
addendum: The radial distance between the top land and the pitch circle. addendum circle: The circle defining the outer diameter of the gear. circular pitch: The distance along the pitch circle from a point on one tooth to a corresponding point on an adjacent tooth. It is also the sum of the tooth thickness and the space width, measured in inches or millimeters. clearance: The radial distance between the bottom land and the clearance circle. contact ratio: The ratio of the number of teeth in contact to the number of those not in contact. dedendum circle: The theoretical circle through the bottom lands of a gear. dedendum: The radial distance between the pitch circle and the dedendum circle. depth: A number standardized in terms of pitch. Full-depth teeth have a working depth of 2/P. If the teeth have equal addenda (as in standard interchangeable gears), the addendum is 1/P. Full-depth gear teeth have a larger contact ratio than stub teeth, and their working depth is about 20% more than that of stub gear teeth. Gears with a small number of teeth might require undercutting to prevent one interfering with another during engagement. diametral pitch (P): The ratio of the number of teeth to the pitch diameter. A measure of the coarseness of a gear, it is the index of tooth size when U.S. units are used, expressed as teeth per inch. pitch: A standard pitch is typically a whole number when measured as a diametral pitch (P). Coarse-pitch gears have teeth larger than a diametral pitch of 20 (typically 0.5 to 19.99). Fine-pitch gears usually have teeth of diametral pitch greater than 20. The usual maximum fineness is 120 diametral pitch, but involute-tooth gears can be made with diametral pitches as fine as 200, and cycloidal tooth gears can be made with diametral pitches to 350. pitch circle: A theoretical circle upon which all calculations are based.
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