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Introduction
This article contains information regarding spur gears,
their use, and their benefits.
You will learn more about topics such as:
What is a Spur Gear?
Types of Spur Gears
Uses for Spur Gears
How Spur Gears are Made
Benefits of Spur Gears
And Much More ...
Chapter One – What is a Spur Gear?
A spur gear is a cylindrical toothed gear with teeth that are
parallel to the shaft and is used to transfer mechanical motion
and control speed, power, and torque between shafts. They are
the most popular types of cylindrical gears and have a simple
design of straight parallel teeth positioned equally around the
circumference of the cylinder barrel. There are several
different designs of spur gears that change according to the
shape and thickness of the gear hub, which changes without
changing the face of the gear.
The popularity of spur gears is due to their use in mechanical
applications where they increase or decrease a device’s speed or
multiply torque by transferring motion and power from one shaft
to another. Spur gears are normally mated in a series to change
motion, speed, and torque quickly and efficiently.
Chapter Two – Types of Spur Gears
The performance of a spur gear is determined by its design,
construction, and materials. An essential part of developing a
spur gear is how they are fabricated, which includes the use of
high quality materials and exacting and precise dimensional
compliance that is necessary to determine a spur gear’s
function.
Although there is a wide range of spur gears from very small
ones to ones that operate conveying systems and motors, there
are factors that are common to all spur gears, which are:
Pitch Circle
The pitch circle is the distance from the face of one tooth to
the next tooth. It divides a gear's teeth into the top of a
tooth, the addendum, and the bottom of the tooth, the dedendum.
If a gear system is designed correctly, pitch circles between
gears will be tangent to one another.
Diametral Pitch
The diametral pitch is a function of a gear’s pitch circle and
is equal to the number of teeth per inch. It is used to
determine what size and type of gear are needed to interlock
with another gear.
Pitch Diameter
Pitch diameter is the outer diameter of a gear as if a circle
was drawn around the midpoint length of each tooth of a gear. It
is used to determine the distance between mating gears, as seen
in the diagram below.
Center Distance
The center distance is the distance between the centers of two
meshed gears and is the sum of the pitch diameters divided by
two.
Spur Gear Addendum
The addendum is the height of the teeth of a gear from the pitch
circle to the top of the teeth.
Gear Dedendum
The dedendum is the depth of a tooth below the pitch circle and
is greater than the addendum for clearance.
Outside Diameter (OD)
The outside diameter is as if a circle were drawn around a spur
gear and touched the tops of the teeth. Its diameter is the
distance to the outermost points of a spur gear’s teeth across
the center of the gear.
Root Diameter
The root diameter is the diameter of a circle that could be
drawn around a gear and coincides with the bottoms of all teeth.
It is a diameter that could be drawn across that circle.
Pressure Angle
The pressure angle is the angle between the pitch line and the
pressure line where the pressure line is tangent to the pitch
point and is normal to the tooth surface. A diagram of it can be
seen in the image below.
Whole Depth
The whole depth is the sum of the addendum and dedendum.
Module
The module measures the tooth size, which is normally measured
in millimeters. When teeth have the same size and module, they
can be easily paired or meshed. The sizes of gear teeth are
indicated by the symbol “m” such as 1m, 2m, and 4m, where the
sizes get larger as the numeric value increases. The module of a
gear can be found by dividing the pitch of a gear by pi (π).
In the examples below, the left gear has a standard tooth
profile while the gear in the center is a high pressure angle
gear. The gear on the right is a high module gear.
Spur Gear Types
Planetary Spur Gear Drive
Planetary spur gear drives, known as epicyclic gearing, consist
of a sun gear, which is the external spur gear, three or more
planet gears, and a ring gear that are combined to make a
planetary gear drive. The spur gears in a planetary spur gear
drive move opposite to each other in the same plane.
The typical spur gear is a basic gear in regard to engineering
since it doesn’t use speciality angles or cuts but has complex
tooth shapes. Planetary gear drives are more complex than
typical spur gears and are more rugged due to the distribution
of the gears around the sun. They are easy to convert to a
different gear ratio by changing the carrier and sun gears.
Planetary spur gear drives are widely used in bicycles,
powertrains, saws and electrical motors.
(from STD Precision Gear and Instrument Inc.)
External Spur Gear
The configuration of an external spur gear is typical of all
types of gears with the teeth of the gear on the cylinder’s
surface. When it meshes with another gear, the gears will rotate
in the opposite direction. The drive gear is normally smaller
than the driven gear.
Internal Spur Gear
The teeth for an internal spur gear are cut on the inner surface
of the gear. The external surface is smooth in the shape of a
perfect oval or circle. The inner gear teeth mesh with a pinion
or smaller gear. The gears rotate in the same direction.
Anti-Backlash Gear
An anti-backlash gear assembly has a free gear and fixed gear
that are mounted to a hub or shaft with the movement of the free
gear restricted by an extension, compression, or torsion spring.
When the free gear is engaged with the mating gear, the spring
pushes the gear forward against the mating tooth or pulls the
tooth back against the mating tooth. This form of control of
backlash is referred to as a spring loaded anti-backlash gear.
Backlash is play between the tooth surfaces of mating gears and
is needed for teeth deflection and heat generated expansion
during gear operation. Clearance between gears is necessary to
let gears mesh and have space for lubricating oil. It is set by
a reduction in tooth thickness and increasing center distance.
Although it is a part of gear performance, certain machines
require high gear positioning accuracy with little to no
backlash.
To meet the need of removing backlash, manufacturers have
developed anti-backlash, no backlash, and zero backlash gears.
Spring loaded anti-backlash gears maintain a constant zero
backlash and come in various forms to meet the needs of an
application.
(from STD Precision Gear and Instrument Inc.)
Type A Spur Gear
A type A spur gear does not have a hub and is flat with a small
hole in the center. The circle of the root diameter is solid
with the small hole placed in its center.
Pin Hub Spur Gear
A pin hub spur gear has a set screw used to secure a pin on the
gear to the shaft. They can be connected to a shaft using a
dowel, spring, roll, or taper pins. The hole in the gear is
drilled to the exact size of the pin for a tight connection. The
set screw used to pin the gear to the shaft is removed to avoid
loosening and falling into the mechanism. The difference in the
various types of pin hub spur gears is the size of the hole
where the gear connects to the shaft.
Keyway Spur Gear
With a keyway spur gear, a slot is cut in the gear’s bore that
fits the slot milled into the shaft. The keyway allows the shaft
and gear to fit snugly together with the proper alignment of the
slots. The purpose of the design is to eliminate slippage
between the shaft and spur gear.
Spline Spur Gear
With a spline spur gear, ridges or teeth are cut into the drive
shaft that matches grooves cut in the bore of the spur gear.
There are different varieties of spline configurations with some
straight like a keyway or involute like gear teeth. The spacing
between the splines varies according to the design of the gear.
Involute spline spur gears can have any number of teeth up to
32.
Split Hub Spur Gear
The split hub has a split along its axial plane, which allows it
to be attached to any shaft by having the split hub tightened
with a clamp to snuggly and securely attach it to the shaft. It
is one of the easiest spur gears to assemble and disassemble.
Split hub spur gears can adjust and configure their position on
the shaft with little effort. The drawback to split hub spur
gears is their size since they tend to take up more space.
Set Screw Spur Gear
Set screw spur gears can have a keyed or round bore with a set
screw in their hub that attaches them to the shaft through the
hub. They work like pin hub spur gears, except that the set
screw is not removed. Set screw spur gears allow for a certain
amount of flexibility in placing the gear and provide a secure
tight fit.
Spur Gear Rack and Pinion
A rack and pinion spur gear set aims to change rotational motion
into linear motion. The pinion of a rack and pinion spur gear
set is a bar of metal with gear teeth. The spur gear is the
drive gear of the set and is referred to as the rack gear. The
benefits of a rack and pinion spur gear set are their
simplicity, large load capacity, and no limit to their length.
Plastic Spur Gears With Metal Core
The positive characteristics of plastic gears are their
lightweight, high rust resistance, silent operation, low cost,
and the ability to operate without lubrication. They are very
durable, strong, and reliable and can easily be interchanged.
Plastic spur gears are the most common form of plastic gear. The
main use of plastic spur gears is in low demand applications as
an alternative to metal gears.
Leading Manufacturers and Suppliers
Chapter Three – How Spur Gears are Made
There are several methods used to produce spur gears, which
include forging, blank machining, cutting, casting, powder
metallurgy, and computer numeric controlled (CNC) manufacturing
to name a few. Regardless of the process, dimensional accuracy
and adherence to tolerances is critical since the slightest
error can prevent the proper meshing between gears. In cases
where exceptional performance is required, spur gears are
forged, cut, or machined.
Spur gears are one of the oldest forms of equipment and have
existed since the time of the Greeks and Romans. The use of more
sophisticated designs began in the 17th Century when the first
attempts were made to calculate velocity ratios of involute
gears. During the first industrial revolution, form and rotating
cutters were introduced, which was followed by the invention of
the hobbing process.
Manufacturing of Spur Gears
Gear Blanks
Regardless of the cutting process, it begins with a gear blank.
The quality of a spur gear depends on the type of material from
which the gear blank is made. High quality spur gears can only
be made from high quality materials, which is a pie shaped
billet.
Milling Process
The milling process can produce all types of gears beyond spur
gears. It involves using a milling machine that has a form
cutter that passes through the gear blank to cut the tooth gap.
In form milling, the workpiece is mounted such that the cutter
can move perpendicular along the axial length of the tooth at
the correct depth. At the end of each cut, the cutter is
withdrawn, and the gear blank rotates for the next cut. The
cutter has the shape of the space between the teeth.
Hobbing Process
In the hobbing process, the gear blank and the hob rotate
simultaneously in a continuous motion such that they mesh as the
teeth are being cut. The tool or hob is fed inward until it
reaches the proper depth and has equally spaced cutting edges.
Hobbing is a fast and accurate process.
The gear blank rotates on its vertical axis as the hob cuts
horizontally. The gear is created by cutting the facets of each
tooth such that it is like the gashes of the hob, which produces
a far more precise profile and tolerance.
Gear Shaping
The gear shaping process can be used to create internal spur
gears and has a cutting tool that is a gear with cutting edges
that moves axially against the inner diameter of the workpiece.
The cutting gear rotates at the same velocity ratio as the gear
being made. The motion of the cutting tool is repeated several
times until the proper depth is reached for the gear teeth. It
is a slow process that involves rotating the tool and workpiece
as the tool continues its oscillating motion.
Gear shaping can produce all of the different varieties of spur
gears with high surface finishes internally and externally. The
shaping tool is similar to a cylindrical gear or rack type gear.
Gear Stamping Process
In the stamping process, a sheet of metal is placed between the
top and bottom dies where the upper die is pressed down on the
lower die cutting out the gear from the sheet. It is a low cost
efficient method for producing lightweight spur gears for medium
duty with no loads. Stamping is restricted by the thickness of
the metal, which ranges in thickness from 0.25 mm or 0.010
inches to 3 mm or 0.125 inches.
Cold Drawing
Cold drawing is capable of forming different types of tooth
configurations. In the cold drawing process, a bar of metal is
pulled, drawn, pushed, or extruded through a series of dies with
the final die having the required shape of the teeth of the
gear. As the rod passes through the dies, it is squeezed to the
shape of each die. The pressure of the process places greater
stress on the surface of the bar.
Once the bars have passed through the dies, they are called
pinion rods, which are put into screw machines to finish the
individual gears. The cold working process increases the
strength of the gear and reduces its ductility. The process may
require several dies aligned in a series to achieve the desired
shape.
Spur Gear Roll Forming
The roll forming of spur gears requires several rotations of the
forming rolls where the rolls are fed slowly during several
revolutions. Top lands of roll formed teeth may not be smooth or
perfect in shape. Since the top land does not affect the action
of the teeth, this deformity does not cause any difficulty.
Spur gears that are roll formed must have at least 18 teeth or
more since spur gears with fewer teeth perform badly.
Forging Spur Gears
The main use of forging in the manufacture of spur gears is the
production of gear blanks for the cutting process. The process
includes an open die, closed die, and hot upset forgings. Aside
from the production of blanks, forging is also used to produce
precision forged spur gears that require little to no finishing.
Precision forging of gears uses closed die hot and cold forging.
In the majority of cases, spur gears are shaped with one blow
with the velocity of the ram supplying the major forging force.
Pancaking is used to produce spur gears, which causes lateral
flow in the die. Of the various types of gears, spur gears are
the easiest to forge. Low alloy steel, brass, aluminum alloys,
stainless steel, and titanium are the metals used in the forging
process.
The goal of precision forging is to produce gears at near net
shape, which means that the gears will not need finishing after
being forged. With hot forging, there is very little waste and
involves casting or injection molding. Compared to cut gears,
forged spur gears have greater load carrying capacity than cut
gears. The grain flow in forged spur gears follows the contour
of the teeth.
The processes described above are a few of the methods that are
used to manufacture spur gears. The choice of how a gear is made
is dependent on several factors including the type of material,
time involved, use of the spur gear, and the manufacturer. What
has not been included is the production of plastic gears, which
can be molded, cast, or extruded.
Chapter Four – Materials Used to Manufacture Spur Gears
The strength, endurance, and performance of spur gears are
dependent on their construction. As with all products, design is
important but relies on the quality of the materials to produce
a product. Nearly every form of material used in the manufacture
of other products can be used to make spur gears, including
steel, brass, plastics, aluminum alloys, grades of stainless
steel, and titanium. Of the wide array of choices, hardened
steel is the most commonly used since it can be honed to prevent
premature wear.
Each type of metal used to make spur gears has a unique and
distinct purpose. Plastic spur gears are noiseless while steel
and stainless steel spur gears are more durable and long
lasting. The choice of materials is based on the torque the gear
will be sending. In those instances, plastic gears are not a
choice since they are not desirable for high torque
applications.
Spur Gear Materials
Plastic Materials
There are several types of plastics used to produce plastic spur
gears, including polyacetal (POM), nylon, polyethylene (UPE),
and polyetheretherketone (PEEK), a ketone polymer. Plastic spur
gears are lightweight, rust resistant, inexpensive to produce,
and can operate without producing friction. They are widely used
in food production, electronics, toys, and medical instruments.
Polyacetal (POM)
POM is a very strong plastic commonly used to produce spur
gears. It can be easily molded, shaped, and formed. Once it
hardens, POM becomes extremely stiff, strong, and abrasion
resistant. The malleability and resilience of POM make it an
ideal material for spur gear manufacturing.
Cast Iron
Cast iron, like POM, can be molded into any shape and is
resistant to rust. The composition of cast iron involves the use
of different ingredients each of which gives cast iron a
different degree of strength and durability. Cast iron is
commonly used to produce machine parts because of its low cost,
rust resistance, and ability to be easily molded and shaped. It
can be unbelievably strong or very weak, depending on the types
of added mixtures.
Stainless Steel
Stainless steel comes in several levels, grades, and
characteristics, with all types having at least 11% chromium.
Other alloys include nickel, manganese, silicon, phosphorus,
sulfur, and nitrogen. Ferritic stainless steels are magnetic,
while austenitic stainless steels are nonmagnetic, martensitic,
and precipitation hardened. Austenitic stainless steels are in
the 300 series of stainless steels, while ferritic stainless
steels are in the 400 series.
The stainless steel that is used the most is 304, which contains
18% chromium and 8% nickel. The most common stainless steel used
for manufacturing spur gears is grade 303, which has a chromium
content of 17% and a 1% sulfur content. The slight addition of
sulfur makes 303 machinable.
When an application needs corrosion resistance, grade 316 is
normally the first choice. It has 16% chromium, 10% nickel, and
2% molybdenum. Grades 303 and 316 are the most common stainless
steels used to manufacture spur gears.
Steel in Spur Gears
Steel is an alloy of iron, carbon, and various other elements.
There are four major steel types: carbon, alloy, stainless, and
tool steel. Of the various types, carbon steel is used the most
to manufacture spur gears because it is easy to machine, is wear
resistant, able to be hardened, available, and inexpensive.
Carbon steels are categorized as mild, medium carbon, and high
carbon, with mild carbon steel having less than 0.3% carbon
content. Each of these types of steel are good for the
manufacture of spur gears.
Induction hardening or laser hardening are used to harden carbon
steel to a Rockwell Hardness scale of 55. The addition of
various alloys to carbon steel makes it stronger, easier to
machine and creates corrosion resistance. All of the types of
alloyed carbon steel are used to manufacture spur gears.
Aluminum Alloys
Aluminum alloys are used to make spur gears for applications
that need a high strength to weight ratio since aluminum is one
third the weight of steel and has a surface that is resistant to
corrosion. It is more expensive than steel but less expensive
than stainless steel. Aluminum alloys are easy to machine, which
offsets its higher cost.
Typical aluminum alloys used to produce spur gears are 2024,
6061, and 7075. Aluminum alloy 2024 is a close relative to
bronze since it is made up of aluminum and copper. The copper in
2024 gives it strength but lowers its corrosion resistance.
Alloy 7075 has zinc and magnesium alloyed with aluminum, which
gives the aluminum increased strength and resistance to load
stress.
Aluminum alloys 2024, 6061, and 7075 can be heated to improve
their hardness. They are commonly used in the manufacture of
spur gears.
Chapter Five – Uses for Spur Gears
Spur gears are the most common form of gear and are found in a
wide range of applications. They perform several important
functions, the most critical of which is providing gear
reduction to mechanical motorized devices. Once a spur gear is
mounted on a parallel shaft, it meshes perfectly with other
gears.
Since the teeth of a spur gear are parallel to the rotational
axis, they do not produce axial thrust, which makes it easy to
mount them with ball bearings. They are cost effective, and
precision engineered products that are easy to use and install.
Spur Gear Uses
Increasing or Decreasing Power
Spur gears are used to increase or decrease the torque or power
on a device and are found in washing machines, blenders, clothes
dryers, construction equipment, pumps, and conveyors. In power
stations, groups of connected spur gears, or trains, are used to
convert energy, such as wind or hydroelectric power, into
electrical power. Spur gears in a train have the same sized
teeth with adjacent gears rotating in opposite directions.
Changing Speed
In applications that require the increase or decrease of speed,
spur gears are an ideal solution. They transfer motion and power
from one shaft to another, which alters the operating speed of
machinery, multiplies torque, and allows for fine tuned control
of positioning systems. It is for this reason that they are
found in clocks to adjust the speed of second, minute, and hour
hands.
Washing Machines
Since spur gears control the speed of applications, they are
used in washing machines to control the rotating motion of a
washing machine. Depending on what cycle the machine is
performing, spur gears assist in increasing or decreasing
torque.
Road Roller
In a road roller, a set of spur gears changes the fast
rotational speed of the engine into a slow rotational speed for
the wheels. This change makes it possible for a road roller to
be able to move its heavy roller.
Sports Car
In a sports car, a smaller rotational force is needed for the
wheels because a sports car is very light. Spur gears used to
move a sports car also change the engine's speed into a slower
rotational speed for the wheels. The wheels are able to turn
faster with a smaller turning force.
Conveyor Systems
Conveyor systems have to move at a controlled speed, producing
high torque. Spur gears are used as a reliable means for
altering the torque of the system. In some types, a self-locking
worm gear is used to power and move the spur gear, where the
worm gear is the drive gear.
Radio Dials
In tuning a radio, precision is necessary to hit the correct
position on the dial. The accuracy and precision of spur gears
allow them to perfectly tune a radio to the chosen channel.
How to Choose the Right Spur Gear
Torque and Speed
The calculation of the torque and speed of a system is essential
when selecting the proper spur gear. This refers to the input
speed and input torque and the output speed and output torque.
Identifying Through Pitch
Pitch is an identifier for spur gears and includes the
diametrical pitch, circular pitch, and module. In the United
States, the designation of pitch is the diametrical pitch (DP),
which is infinite. To make choices easier, a specific set of DPs
has been developed.
Teeth Geometry
Gear teeth geometry is determined by the pitch, depth of the
teeth, and pressure angle. A complex set of formulas are
required to make the teeth geometry calculation.
Idler Gear
Idler gears are used to change the directional rotation of the
output gear. When designing spur gears, it is necessary to know
whether an idler gear is required.
Gear Trains
Gear trains are used to pass power between shafts and are a
series of spur gears with similar gear shapes and teeth.
Stress Calculations
Several forms of stress calculations must be made regarding a
spur gear system. The purpose of the calculations is to ensure
the safety and strength of the system.
Type of Material
The type of material determines the longevity of a spur gear and
its strength, reliability, and endurance. This aspect of the
selection process is normally the first consideration and is
carefully planned by designers and engineers.
Chapter Six – Benefits of Spur Gears
Spur gears are one of the most popular types of gears and are
used in an endless number of applications, from simple toys to
complex industrial machinery. They have a simple straight tool
design that can be configured and shaped to fit the needs of any
application. The parallel teeth are placed an equal distance
apart around the circumference of a cylinder body with a core
that fits over a shaft.
Spur Gear Benefits
Simple Design
The simple compact design of spur gears makes them easy to
create, design, and configure. They can fit easily into
restricted and tight spaces with few limitations.
Precision and Accuracy
This aspect of spur gears is one of the major reasons for their
wide usage. Spur gears increase and decrease speed with
exceptional precision and accuracy at a constant velocity.
Gear Reliability
It is very unusual and unlikely for a spur gear to fail during
use. Their durability and strength make it next to impossible
for them to slip, break, or malfunction.
Production Cost
This is another factor that has made spur gears so
indispensable. Their simplicity makes it easier to manufacture
them, which greatly decreases their production cost. Large
volumes of spur gears can rapidly be produced with little waste.
Spur Gear Efficiency
Efficiency works in conjunction with reliability. During the
useful life of a spur gear system, the gears are able to
transfer large amounts of power across several gear trains
without any or minimal loss of power.
Straight Teeth
The straight teeth of spur gears eliminates the likelihood of
axial thrust since power is transmitted in a straight line at
the pitch angle of a spur gear’s teeth.
Conclusion
A spur gear is a cylindrical toothed gear with teeth parallel to
the shaft and is used to transfer mechanical motion as well as
control speed, power, and torque between shafts.
The performance of a spur gear is determined by its design,
construction, and materials. An essential part of the
development of a spur gear is how they are fabricated, which
includes the use of high quality materials and exacting and
precise dimensional compliance that is used to determine a spur
gear’s function.
There are several methods used to produce spur gears, which
include forging, blank machining, cutting, casting, powder
metallurgy, and computer numeric controlled manufacturing to
name a few. Regardless of the process, dimensional accuracy and
adherence to tolerances is critical since the slightest error
can prevent the proper meshing between gears. In cases where
exceptional performance is required, spur gears are forged, cut,
or machined.
Nearly every form of material used in the manufacture of other
products can be used to make spur gears, including steel, brass,
plastics, aluminum alloys, grades of stainless steel, and
titanium. Of the wide array of choices, hardened steel is the
most commonly used since it is honed to prevent premature wear.
Spur gears are one of the most popular types of gears and are
used in an endless number of applications, from simple toys to
complex industrial machinery. They have a simple straight tool
design that can be configured and shaped to fit the needs of any
application.
Leading Manufacturers and Suppliers
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