all about gears

8/19/2019 All About Gears

1/12

All about gears (kinds, applications,)

GearsGears are Power transmission elements. It is the Gears that decide the torque, speed and direction of rotation of all

the driven machine elements. Broadly speaking, Gear types may be grouped into five major categories. hey are!pur, "elical, Bevel, "ypoid, and #orm. $ lot of intricacies are there in the different types of gears. $ctually hechoice of gear type is not a very easy process. It is dependent on a number of considerations. %actors that go into itare physical space and shaft arrangement, gear ratio, load, accuracy and quality level.

Types of Gears

Types of Gears

$ number of gears are manufactured using different materials and with different performance specifications dependingon the industrial application. hese gears are available in a range of capacities, si&es and speed ratios, but the mainfunction is to convert the input of a prime mover into an output with high torque and low 'P(. hese range of gearsfind use in almost every industry right from agriculture to aerospace, from mining to paper and pulp industry. !ome ofthe popular types of gears in use are )

Spur Gears

Spur Gear


2/12

!pur gears are straight*toothed gears having radial teeth used to transmit power and motion between parallel a+es.hese gears are widely used for speed increase or reduction, high torque, resolution for positioning systems.

hese gears can either be mounted on a hub or a shaft. he gears are available in different si&e, design, shape andalso offer a variety of features and functions to cater to different industrial requirements.

Materials Used!pur gears are fabricated from superior quality materials, like)

•(etal* steel, cast iron, brass, bron&e and stainless steel.

• Plastic* acetal, nylon and polycarbonate.

(aterials used to manufacture these gears are used keeping in mind certain factors including design life, powertransmission requirements, noise generation.

Important Specifications to be Considered

• Gear center

• Bore diameter

• !haft diameter

Use of Spur Gearshese gears find wide application in a number of fields including )

• $utomobiles• e+tiles

• Industrial engineering

Bevel Gears

Bevel Gear

Bevel gears are mechanical devices used for transmitting mechanical power and motion. hese gears are widely usedfor transmitting power and motion between nonparallel a+es and are designed to transmit motion between intersectinga+es, generally at right angles. he teeth on bevel gear can be straight, spiral or hypoid. he gears are suitable whenthe direction of a shafts rotation needs to be changed.

Materials used(aterials used to manufacture these gears are used keeping in mind certain factors including design life, powertransmission requirements, noise generation. !ome of the important materials used are )

•

(etal * !teel, cast iron and stainless steel.• Plastic * $cetal and polycarbonate.

Important specifications to be considered

• Gear center


3/12

• Bore diameter

• !haft diameter

Use of Bevel Gear hese gears find wide application in a number of fields including )

• $utomotive industry

• e+tile industry

• Industrial engineering products

Helical Gears

Helical Gears

"elical gear is a popular type of gear having its teeth cut at an angle, thus allowing for more gradual and smoothermeshing between gear wheels. he helical gears are a refinement over spur gears.

he teeth on helical gears are specially cut at an angle, so as to face the gear. $s two teeth on the gear systemengage, it starts a contact on one end of the tooth which gradually spreads with the gear rotation, until the time whenboth the tooth are fully engaged.

he gears are available in different si&es, shapes and designs to meet the customer specifications.

Materials Usedhese gears can be manufactured from superior quality materials including stainless steel, steel, cast iron, brass etc.depending on the application.

Use of Helical Gearshese gears are used in areas requiring high speeds, large power transmission, or where noise prevention is

important.• $utomobiles

• e+tile

• $erospace

• -onveyors

Worm Gears


4/12

Worm Gear

Worm Gear

$ worm gear is a type of gear, engaging with a worm to significantly reduce rotational speed, or allowing higher torque

to be transmitted. he gear can achieve a higher gear ratio than spur gears of the same si&e.

Materials Used#orm gears can be constructed from a number of materials depending on the end application. !ome of the popularlyuse materials are )

• Brass

• !tainless steel

• -ast iron

• $luminum

• "ardened steel

he gears can operate under difficult conditions and have the ability to achieve large speed reductions. he gears also

transmit high loads at high speed ratios.

Types of Worm Gears

• on*throated

• !ingle*throated


5/12

• /ouble*throated

Use of Worm Gearshese gears find application in )

• 0lectric motors

• $utomotive components

Differential Gears

Differential Gear

/ifferential gears are referred to an arrangement of gears, connecting two a+les in the same line and dividing thedriving force between them. 1ne a+le is allowed to turn faster than the other. hese gears are often used in

automotive industry for allowing a difference in a+le speed on curves.

In automobiles, the gear system allows the wheels to rotate at different speeds and simultaneously supplying each ofthem with equal torque. he gears are specially designed to create a differential and consist of pinion and turnablegears.

Types of Differential Gears

• !traight 2ine /ifferential Gears

• 'otary /ifferential Gears

Materials Usedhe gears are manufactured using materials including )

• $luminum alloys

• -ast iron

• !tainless steel

Use of Differential Gearshe gear is e+tensively used in the automobile industry for effective and efficient working of vehicles. hese gears donot create noise and also help in speed differential.

Ground Gears


6/12

$s generally seen grinding is most of the time conceived in conte+t of quantity fabrication of superior quality gears asa form of secondary refining procedure. #e incline to forget that grinding is essentially a basic process in the steptowards production of case hardened gears. (oreover, the teeth of precision*engineered fine*pitch gears completelyground from the blank itself.

he advent of trawling also led to the development and manufacturing of Ground Gears. 0ver since then ground gearshave made substantial improvement in the terms of designing and component accuracy. hese gears assure hightransmission accuracy and deliver superior efficiency, greater load capacity, and correction of profile and durability.

Ground gears can be made using different materials, such as cast iron, carbon steel, alloy steel, hardened steel,bron&e, and more.

Advantaes of Ground GearsGround Gears offer various advantages to its users, some of which are)

• "igh Precision) $chieving high precision is not a difficult task for ground gears since in the grinding process,

there is little removal of material in the final pass.

• !uperior !urface %inish) Grinding makes the surface of ground gears more shiny than that obtained from any

other machining technique.

• Improved %le+ibility) "ardened steel alloys can be used to developed into ground gears that gives its added

fle+ibility.

• (inimal !urface !tress) here is minimum residual surface stress in ground gears.

• 2oad -arrying -apacity) Ground Gears e+hibit a higher load carrying capacity.

• (inimal #ear and ear) Ground gears have minimal wear and tear that results in prolonged life.

!imitations of Ground Gearshough ground gears offer multiple benefits and advantages, they too have some limitations)

• here is a limit to grinding procedures and that is to ferrous material.

• "ard metals can be grind in an efficient and better way than the soft ones.

• In case of worm or helical gears, grinding may not be the ideal solution. his is due to the reason that it often

involves deviations in terms of removal and profile.

• Gear grinding machines are not as popular as hobbing machinery.

• Grinding demands higher costs, as it is a secondary operation.


7/12

Applicationshese gears find wide application in a number of fields including )

• "igh !peed 'otation) Ground gears are ideal for uses in applications that need noise and vibration resistance

in the case of high*speed gear drives. $n e+ample can be that of ground spur gears.

• Positioning) -P 'acks and Pinions are recommended for perfect positioning applications. In these cases,

ground gears are used in calculating for reducing pitch errors.

"iln Girt# Gears

Kiln Girth Gears

3iln girth gears are large diameter 4 large module gears that are manufactured using large gear cutting machines. hegirth gear of a rotary kiln comes with a diameter of 5678 mm with 95 module and ::; teeth. hese gears are verydifficult to fabricate using the conventional techniques of gear cutting. In manufacturing of these gears, teeth cutting isdone using face mill cutter on a hori&ontal boring machine, which generally reduces the time taken in teeth cutting toone*third of the original one.

he kiln girth gears come under the category of industrial gears and the commonly used material for these gears is 8;-r (o 8. hese gears are widely used in cement industry, sugar industry and other industrial purposes andapplications.

0ngineered to precision, kiln girth gears are known to deliver superior efficiency and flawless performance and theiroverall life depends on proper alignment and lubrication. hese gears are easy to install and take less time ascompared to others.

Industrial Applications!ome of the important applications of girth gears include)

• "eavy (achinery Industries

• (etal -asting Industries

• (etal Processing Industries

• -onstruction Industries

$recision Gears


8/12

Precision gears are custom*made actuators that can be designed for varying uses and applications. hese gears aregenerally used in applications under conditions of light loading. Precision gears are generally preferred for theirprecise, smooth, compact, noiseless and reliable performance.

Precision gears can be manufactured as per the customers drawings or based on a functional description dependingon the type of application. he different types of precision gear products include, * spur gears, helical gears, wormgears, anti*backlash gears, cluster gears, clutch gears, face gears, planetary gears, gear assemblies, gear bo+es,bevel gears, miter gears, metric gears, internal gears, idler gears, gear rack < pinion, worms, worm shafts, splines,spline shafts, se shafts, and more. hese gears can be manufactured as per the e+act customer specifications oraccording to application need.

he quality and performance of a precision gear depends on the quality of blank in which it is cut. hus it is essentialto hold tight tolerances without grinding.

Precision gears are known for their trouble free superior performance, long service life, and e+cellent surface finishand customi&ation capability. hese gears are used in a variety of industrial applications, such as heavy machineryIndustry, metal casting, metal processing, construction, and more.

%ac& Gears

$ rack is generally used for converting rotational motion into linear motion. It is a flat bar onto which the teeth of apinion gear are engaged. It is a kind of gear whose a+is is at infinity. hese gears are designed to accommodate awide variety of applications.

Materials Used $ variety of materials are used keeping in mind the application. !ome popularly used materials are )

• Plastic

• Brass

• !teel


9/12

• -ast Iron

hese gears ensure quieter and smoother operation. he mechanism provides less backlash and greater steeringfeel.

Use of %ac& Gear he gear is commonly used in steering mechanism of cars. 1ther important applications of rack gears include )

• -onstruction equipment

• (achine tools

• -onveyors

• (aterial handling

• 'oller feeds

Sproc&ets

$ sprocket is a gear having metal teeth that meshes with a chain. $lso known as a cog wheel, it is a small toothed ringthat can fit onto the rear wheel. It is a thin wheel having teeth that engage with a chain.

Materials Used $ variety of materials can be used to manufacture superior quality sprockets used in different industries. !ome of thematerials used are )

• !tainless steel

• "ardened steel

• -ast iron

• Brass

Use of Sproc&etshis simple gear finds application in diverse areas including )

• %ood industry

• Bicycles

• (otorcycles

• -ars

• anks

• Industrial machines

• (ovie projectors and cameras

Sement Gears


10/12

he segment gear, as the name suggests, is basically a gear wheel. hese gear wheels are composed of a largenumber of pieces that are small parts of a circle. $ segment gear is connected to the arms or trappings of the waterwheel.

he segment gear comes with a part for receiving or communicating the reciprocating motion from or to a cogwheel.hese gears also comprise of a sector of a circular ring or gear. here are also cogs on the periphery.

!egment Gears are available in various finishes, such as untreated or heat*treated and can be designed as a singlecomponent or as an entire system.

Applications!egment gears, which are basically gear wheels, are used in variety of industrial uses and applications. hese gearsoffer various advantages such as improved fle+ibility, superior surface finish, high precision and minimum wear andtear. !ome of the uses of segment gears include)

• /efense

• 'ubber

• 'ailways

$lanetary Gear

Planetary gear is an outer gear that revolves around a central sun gear. Planetary gears can produce different gearratios depending on which gear is used as the input, which one is used as the output.

Materials Used

he gears can be constructed from a variety of materials including )• !tainless steel

• "ardened steel

• -ast iron

http://industries-news.blogspot.com/2015/06/epicyclic-gearing-how-does-it-work.htmlhttp://industries-news.blogspot.com/2015/06/epicyclic-gearing-how-does-it-work.html


11/12


12/12

1ne of the simplest and most used gear units, e+ternal gears are e+tensively used in gear pumps and other industrialproducts for smooth functioning. hese gears have straight teeth parallel to the a+is. he teeth transmit rotary motionbetween parallel shafts.Materials Usedhe gears can be constructed from a variety of materials including )

• !tainless steel

• "ardened steel

• -ast iron

• $luminum

he kind of material used in manufacturing these gears depends on the end use they are being put to.

Use of '(ternal Gearshese gears are used in diverse fields including )

• -oal industry

• (ining

• !teel plants

• Paper and pulp industry

all about gears

Documents