Abstract
The analytical method of gear design is calculation-intensive and it is usually difficult to achieve optimum backlash and interference-free involute profile that are required to generate geometrical compatibility in a pair of meshing gears when design procedure is entirely based on this method. Some amount of backlash is often required in the assembly of gears but excess backlash can lead to increase vibration and wear of the gear assembly. Also, interference-risk profile can result in undercutting of gear tooth. This paper optimized a spur external involute-profile gear by developing an application for the modeling of its geometrical compatibility using Matlab®. The application uses existing models to test for interference and a proposed model to determine effective backlash in a gear. The backlash values resulting from the application are more confined and the model is applicable to a wider range of modules suggested by American Gear Manufacturers Association. Simulation of the gear-set in Solidworks® for kinematic geometry presents an interference-free tooth contour and an effective backlash.
Highlights
A gear is a wheel on which toothed members are cut to transmit rotary motion or rotational force from one shaft to another [1, 2]
The complexity is not unconnected with the combined basic design requirements imposed by the fundamental law of gearing, the kinematics of the gear tooth profile, the variable loading of gear tooth, the joint rolling and sliding contact between curved tooth surfaces, and the gear interaction with other machine elements [9]
The developed application was used to determine the effective backlash during the modeling of the gear tooth shape
Summary
A gear is a wheel on which toothed members are cut to transmit rotary motion or rotational force (torque) from one shaft to another [1, 2]. Involute gears are mission critical and indispensable elements in the design of motion and power transmission applications [5]. The ratio must not vary between when a given pair of teeth comes into mesh and when they go out of mesh [3] Any such variation will produce oscillation in the output velocity and torque, even if the input is constant with time [10]. A design objective to conform with the fundamental law of gearing and to obtain gear teeth that will run smoothly through the angle of action must consider three major design tasks, viz: (1) to avoid interference, (2) to achieve a contact ratio greater than one to assure of one tooth pair (preferably more) is in contact at all times and (3) to provide an optimum amount of backlash in the mesh [9]. Backlash is the clearance between the width of space and tooth thickness, both measured on the pitch circle, to compensate for unavoidable inaccuracies in gear assembly [12, 4]
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