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Welcome to My Presentation
Different types of Gear & Maintenance of
Gear
Made By
Md. Raijul Islam
Dept. of Textile Engineering
BGMEAuniversity of Fashion&
Technology(BUFT)
Session: 2013-2017
Email: raijulbuft@gmail.com
3
Gear
 A gear is a Mechanical component used to
transmit power and motion
 Key operations
 Reversing the direction of rotation
 Altering angular orientation of rotary motion
 Convert rotary motion into linear motion &
vice versa
 Altering speed ratios
4
Characteristics
 In geometry gears are
 Toothed wheels
 Transmit motion & power from one shaft to
another when they are closer to each other (not
too far apart)
 Constant velocity ratio is desired
 In comparison with belt, chain & friction
devices are : More compact
 Operate at high speeds
 Precise timing
 Large power
5
Characteristics (Contd)
 Gears can mesh with any component having
compatible teeth
 Gears of unequal (sizes) diameters can be
combined to produce mechanical advantage
 Rotational speed & torque of second gear may
be different from that of the first
6
 In a set of gears, the smaller gear is called a
pinion
 The larger gear is called a wheel or simply
gear
Characteristics(Contd)
TYPES OF GEARS
• Spur Gear
• Helical Gear
• Herringbone Gear
• Bevel Gear
• Worm Gear
• Rack and Pinion
• Internal and External Gear
• Face Gear
• Sprcokets
Gears - It’s Classification
Spur Gear
Spur gears
Most common
type
Transfer
power between
parallel shafts
Good
mechanical
efficiency
Cheapest
Helical Gear
Helical gears
Variation of spur
gears
Teeth are slanted
at an angle
Allowing more
teeth coming in
contact with each
other
Wide load
distribution
Less noise
Herringbone Gear
Herringbone gears
Double helical
gears
Can absorb axial
thrust within the
gears
Bevel Gear
 Bevel gears
Connect two
intersecting shafts
Making an angle
with one another
Slightly less
efficient than spur
gear
More expensive
Noisy at high speed
Bevel/Miter Gear
Spiral Bevel Gears Zero Bevel Gears
Worm Gear
 Worm & worm gear
Shafts are generally
but not necessarily at
right angles in
different planes
Axes are orthogonal
to each other but not
intersecting
Expensive
Efficiency drops off
quickly as gear ratio
increases
Rack and Pinion
Rack & pinion
arrangement
Convert
rotational motion
into translational
motion
Internal and External Gear
Internal Gear External Gear
Face Gear
Sprockets
• Sprockets are used to run chains
or belts. They are typically used in
conveyor systems.
• They are used in chain drives, in
motorcycles and bicycles.
Good Maintenance Practice
During normal periods of operation, gear-drive
units should be given daily routine inspection,
consisting of visual inspection and observation for
oil leaks or unusual noises. If oil leaks are evident,
the unit should be shut down until the cause of the
noise has been determined and corrected. Check
all oil levels at least once a week. Under normal
conditions, the maximum operating temperature
should not exceed 180F (82C). Generally,
pressure-lubricated units are equipped with a filter
which should be cleaned periodically.
Gear failure can occur in various modes. In this chapter details of failure are given. If care is
taken during the design stage itself to prevent each of these failure a sound gear design can
be evolved. The gear failure is explained by means of flow diagram in Fig.
GEAR TOOTH FAILURE
Different modes of failure
Wear on Gear
Wear is a general term describing loss of material from the
contacting surfaces of gear teeth.
• Maintenance:A certain
amount of smoothing and
polishing is expected
during “running-in” of new
gearsets.
Scoring is due to combination of two distinct activities: First, lubrication failure in the
contact region and second, establishment of metal to metal contact. Later on,
welding and tearing action resulting from metallic contact removes the metal rapidly
and continuously so far the load, speed and oil temperature remain at the same
level. The scoring is classified into initial, moderate and destructive.
INITIAL SCORING
Initial scoring occurs at the high
spots left by previous machining.
Lubrication failure at these spots
leads to initial scoring or scuffing as
shown in Fig. (h). Once these high
spots are removed, the stress
comes down as the load is
distributed over a larger area. The
scoring will then stop if the load,
speed and temperature of oil remain
unchanged or reduced. Initial
scoring is non-progressive and has
corrective action associated with it. Fig. (h) Initial scoring
SCORING
MODERATE SCORING
After initial scoring if the
load, speed or oil
temperature increases,
the scoring will spread
over to a larger area. The
Scoring progresses at
tolerable rate. This is
called moderate scoring
as shown in Fig. (i).
Fig. (i) Moderate scoring
SCORING
DESTRUCTIVE SCORING
After the initial scoring, if
the load, speed or oil
temperature increases
appreciably, then severe
scoring sets in with heavy
metal torn regions
spreading quickly
throughout as shown in
Fig.(j). Scoring is normally
predominant over the pitch
line region since
elastohydrodynamic
lubrication is the least at
that region. In dry running
surfaces may seize.
Fig. (j) Destructive scoring
SCORING
 Cause:
• Excessive surface pressure.
• High Surface Speed.
• Inadequate supply of lubricant result in the breakdown of the oil film.
 Remedies:
• Selecting the parameters such as surface speed, surface pressure and
the flow of lubricant in such a way that the resulting temperature at the
contacting surfaces is within permissible limits.
• The bulk temperature of the lubricant can be reduced by providing fins
on the outside surface of the gear box and a fan for forced circulation
of air over the fins.
SCORING
Pitting is a surface fatigue failure of the gear tooth. It
occurs due to repeated loading of tooth surface and the
contact stress exceeding the surface fatigue strength of
the material. Material in the fatigue region gets removed
and a pit is formed. The pit itself will cause stress
concentration and soon the pitting spreads to adjacent
region till the whole surface is covered. Subsequently,
higher impact load resulting from pitting may cause
fracture of already weakened tooth. However, the failure
process takes place over millions of cycles of running.
There are two types of pitting, initial and progressive.
PITTING OF GEARS
INITIAL / INCIPIENT PITTING
Initial pitting occurs during running-in
period wherein oversized peaks on the
surface get dislodged and small pits of
25 to 50 μm deep are formed just below
pitch line region. Later on, the load gets
distributed over a larger surface area
and the stress comes down which may
stop the progress of pitting.
Fig. (e) Initial pitting
PITTING OF GEARS
In the helical gear shown in Fig. (e). pitting started as a
local overload due to slight misalignment and progressed
across the tooth in the dedendum portion to mid face.
Here, the pitting stopped and the pitted surfaces began to
polish up and burnish over. This phenomenon is common
with medium hard gears. On gears of materials that run in
well, pitting may cease after running in, and it has
practically no effect on the performance of the drive since
the pits that are formed gradually become smoothed over
from the rolling action. The initial pitting is non-
progressive.
PITTING OF GEARS
Cause:
• Errors in tooth profile.
• Surface irregularities.
• Misalignment.
Remedies:
• Precise machining of gears.
• Correct alignment of gears.
• Reducing the dynamic loads.
Initial Pitting:
PITTING OF GEARS
Pitting begins on the tooth
flanks near the line along
the tooth passing through
the pitch point where there
are high friction forces due
to the low sliding velocity.
Then it spreads to the
whole surface of the flank.
Tooth faces are subjected to
pitting only in rare cases.
Fig. (f) shows how in
destructive pitting, pitting
has spread over the whole
tooth and weakened tooth
has fractured at the tip
leading to total failure
Fig. (g) Whole tooth is destroyed by extensive pitting
PITTING OF GEARS
Cause:
• Load on the gear tooth exceeds the surface
endurance strength of the material.
Remedies:
• Designing the gears in such a way that the
wear strength of the gear tooth is more than
the sum of static and dynamic loads.
• The surface endurance strength can be
improved by increasing the surface hardness.
Destructive Pitting:
PITTING OF GEARS
Abrasive wear is the principal reason for the failure of open gearing and closed gearing of
machinery operating in media polluted by abrasive materials. Examples are mining
machinery; cement mills; road laying, building construction, agricultural and transportation
machinery, and certain other machines. In all these cases, depending on the size, shape and
concentration of the abrasives, the wear will change. Abrasive wear is classified as mild and
severe.
MILD ABRASION
Mild abrasion is noticed when there is ingress of fine dust particles in lubricating oil
which are abrasive in nature. Since abrasive is very fine, the rate of metal removal is
slow. It takes a long time for perceptible wear.
Fig (a) Mild abrasion
ABRASIVE WEAR
The surface appears as though it is polished. A spiral bevel pinion with mild abrasion is
shown in Fig. (a) Mild abrasive wear is faced in cement mills, ore grinding mills. Fine
dust particles entering the lubricating medium cause three body abrasions. The prior
machining marks disappear and surface appears highly polished as shown in Fig.(b).
Noticeable wear occurs only over a long time. Sealing improvement and slight
pressurization of the gear box with air can reduce the entry of dust particles and
decrease this wear.
Fig. (b) Mild abrasion
ABRASIVE WEAR
 Cause:
• Foreign particles in the lubricant like dirt,
rust, weld spatter or metallic debris can
scratch the tooth surface.
 Remedy:
• Provision of oil filters.
• Increasing surface hardness.
• Use of high viscosity oils.
ABRASIVE WEAR
SEVERE ABRASION
This wear occurs due to ingress of larger abrasive particles in the lubricating medium
and higher concentration of the particles. The particles will plough a series of groove on
the surface in the direction of sliding on the gear tooth as seen in the Fig. (c). High rate
of wear in this case will quickly reduce the tooth thickness. Thinned tooth may later on
fracture leading to total failure.
Fig. (c) Severe abrasion
ABRASIVE WEAR
Miscellaneous tooth-surface
deteriorations
Burning can result in severe wear and
surface deterioration of the previously
described types owing to loss of
hardness from high temperatures.
Remedy:
 To reduce friction, look first to the
lubricant.
 Extreme pressure lubricants will
eliminate gear-tooth burning.
Corrosive wear is due to the chemical action of the lubricating oil or the additives.
Tooth is roughened due to wear and can be seen in the Fig.(d1). Chemical wear of
flank of internal gear caused by acidic lubricant is shown in Fig. (d2)
(d1)
(d2)
Fig. d Corrosive wear
CORROSIVE WEAR
 Cause: Corrosive of the tooth is caused by
corrosive elements such as
• Extreme pressure additives present in lubricating
oils.
• Foreign materials.
 Remedies:
• Providing complete enclosure for the gears free
from external contamination.
• Selecting proper additives.
• Replacing the lubricating oil at regular intervals.
CORROSIVE WEAR
CONCLUSION
Maintenance of gear drives involves proper selection, proper
installation, proper loading of the unit,proper lubrication, and
periodic inspection. Metallic gears have tremendous service
life when properlyused and cared for.
THANK YOU

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Gear Maintenance and Types

  • 1. Welcome to My Presentation Different types of Gear & Maintenance of Gear
  • 2. Made By Md. Raijul Islam Dept. of Textile Engineering BGMEAuniversity of Fashion& Technology(BUFT) Session: 2013-2017 Email: raijulbuft@gmail.com
  • 3. 3 Gear  A gear is a Mechanical component used to transmit power and motion  Key operations  Reversing the direction of rotation  Altering angular orientation of rotary motion  Convert rotary motion into linear motion & vice versa  Altering speed ratios
  • 4. 4 Characteristics  In geometry gears are  Toothed wheels  Transmit motion & power from one shaft to another when they are closer to each other (not too far apart)  Constant velocity ratio is desired  In comparison with belt, chain & friction devices are : More compact  Operate at high speeds  Precise timing  Large power
  • 5. 5 Characteristics (Contd)  Gears can mesh with any component having compatible teeth  Gears of unequal (sizes) diameters can be combined to produce mechanical advantage  Rotational speed & torque of second gear may be different from that of the first
  • 6. 6  In a set of gears, the smaller gear is called a pinion  The larger gear is called a wheel or simply gear Characteristics(Contd)
  • 8. • Spur Gear • Helical Gear • Herringbone Gear • Bevel Gear • Worm Gear • Rack and Pinion • Internal and External Gear • Face Gear • Sprcokets Gears - It’s Classification
  • 9. Spur Gear Spur gears Most common type Transfer power between parallel shafts Good mechanical efficiency Cheapest
  • 10. Helical Gear Helical gears Variation of spur gears Teeth are slanted at an angle Allowing more teeth coming in contact with each other Wide load distribution Less noise
  • 11. Herringbone Gear Herringbone gears Double helical gears Can absorb axial thrust within the gears
  • 12. Bevel Gear  Bevel gears Connect two intersecting shafts Making an angle with one another Slightly less efficient than spur gear More expensive Noisy at high speed
  • 13. Bevel/Miter Gear Spiral Bevel Gears Zero Bevel Gears
  • 14. Worm Gear  Worm & worm gear Shafts are generally but not necessarily at right angles in different planes Axes are orthogonal to each other but not intersecting Expensive Efficiency drops off quickly as gear ratio increases
  • 15. Rack and Pinion Rack & pinion arrangement Convert rotational motion into translational motion
  • 16. Internal and External Gear Internal Gear External Gear
  • 18. Sprockets • Sprockets are used to run chains or belts. They are typically used in conveyor systems. • They are used in chain drives, in motorcycles and bicycles.
  • 19. Good Maintenance Practice During normal periods of operation, gear-drive units should be given daily routine inspection, consisting of visual inspection and observation for oil leaks or unusual noises. If oil leaks are evident, the unit should be shut down until the cause of the noise has been determined and corrected. Check all oil levels at least once a week. Under normal conditions, the maximum operating temperature should not exceed 180F (82C). Generally, pressure-lubricated units are equipped with a filter which should be cleaned periodically.
  • 20. Gear failure can occur in various modes. In this chapter details of failure are given. If care is taken during the design stage itself to prevent each of these failure a sound gear design can be evolved. The gear failure is explained by means of flow diagram in Fig. GEAR TOOTH FAILURE Different modes of failure
  • 21. Wear on Gear Wear is a general term describing loss of material from the contacting surfaces of gear teeth. • Maintenance:A certain amount of smoothing and polishing is expected during “running-in” of new gearsets.
  • 22. Scoring is due to combination of two distinct activities: First, lubrication failure in the contact region and second, establishment of metal to metal contact. Later on, welding and tearing action resulting from metallic contact removes the metal rapidly and continuously so far the load, speed and oil temperature remain at the same level. The scoring is classified into initial, moderate and destructive. INITIAL SCORING Initial scoring occurs at the high spots left by previous machining. Lubrication failure at these spots leads to initial scoring or scuffing as shown in Fig. (h). Once these high spots are removed, the stress comes down as the load is distributed over a larger area. The scoring will then stop if the load, speed and temperature of oil remain unchanged or reduced. Initial scoring is non-progressive and has corrective action associated with it. Fig. (h) Initial scoring SCORING
  • 23. MODERATE SCORING After initial scoring if the load, speed or oil temperature increases, the scoring will spread over to a larger area. The Scoring progresses at tolerable rate. This is called moderate scoring as shown in Fig. (i). Fig. (i) Moderate scoring SCORING
  • 24. DESTRUCTIVE SCORING After the initial scoring, if the load, speed or oil temperature increases appreciably, then severe scoring sets in with heavy metal torn regions spreading quickly throughout as shown in Fig.(j). Scoring is normally predominant over the pitch line region since elastohydrodynamic lubrication is the least at that region. In dry running surfaces may seize. Fig. (j) Destructive scoring SCORING
  • 25.  Cause: • Excessive surface pressure. • High Surface Speed. • Inadequate supply of lubricant result in the breakdown of the oil film.  Remedies: • Selecting the parameters such as surface speed, surface pressure and the flow of lubricant in such a way that the resulting temperature at the contacting surfaces is within permissible limits. • The bulk temperature of the lubricant can be reduced by providing fins on the outside surface of the gear box and a fan for forced circulation of air over the fins. SCORING
  • 26. Pitting is a surface fatigue failure of the gear tooth. It occurs due to repeated loading of tooth surface and the contact stress exceeding the surface fatigue strength of the material. Material in the fatigue region gets removed and a pit is formed. The pit itself will cause stress concentration and soon the pitting spreads to adjacent region till the whole surface is covered. Subsequently, higher impact load resulting from pitting may cause fracture of already weakened tooth. However, the failure process takes place over millions of cycles of running. There are two types of pitting, initial and progressive. PITTING OF GEARS
  • 27. INITIAL / INCIPIENT PITTING Initial pitting occurs during running-in period wherein oversized peaks on the surface get dislodged and small pits of 25 to 50 μm deep are formed just below pitch line region. Later on, the load gets distributed over a larger surface area and the stress comes down which may stop the progress of pitting. Fig. (e) Initial pitting PITTING OF GEARS
  • 28. In the helical gear shown in Fig. (e). pitting started as a local overload due to slight misalignment and progressed across the tooth in the dedendum portion to mid face. Here, the pitting stopped and the pitted surfaces began to polish up and burnish over. This phenomenon is common with medium hard gears. On gears of materials that run in well, pitting may cease after running in, and it has practically no effect on the performance of the drive since the pits that are formed gradually become smoothed over from the rolling action. The initial pitting is non- progressive. PITTING OF GEARS
  • 29. Cause: • Errors in tooth profile. • Surface irregularities. • Misalignment. Remedies: • Precise machining of gears. • Correct alignment of gears. • Reducing the dynamic loads. Initial Pitting: PITTING OF GEARS
  • 30. Pitting begins on the tooth flanks near the line along the tooth passing through the pitch point where there are high friction forces due to the low sliding velocity. Then it spreads to the whole surface of the flank. Tooth faces are subjected to pitting only in rare cases. Fig. (f) shows how in destructive pitting, pitting has spread over the whole tooth and weakened tooth has fractured at the tip leading to total failure Fig. (g) Whole tooth is destroyed by extensive pitting PITTING OF GEARS
  • 31. Cause: • Load on the gear tooth exceeds the surface endurance strength of the material. Remedies: • Designing the gears in such a way that the wear strength of the gear tooth is more than the sum of static and dynamic loads. • The surface endurance strength can be improved by increasing the surface hardness. Destructive Pitting: PITTING OF GEARS
  • 32. Abrasive wear is the principal reason for the failure of open gearing and closed gearing of machinery operating in media polluted by abrasive materials. Examples are mining machinery; cement mills; road laying, building construction, agricultural and transportation machinery, and certain other machines. In all these cases, depending on the size, shape and concentration of the abrasives, the wear will change. Abrasive wear is classified as mild and severe. MILD ABRASION Mild abrasion is noticed when there is ingress of fine dust particles in lubricating oil which are abrasive in nature. Since abrasive is very fine, the rate of metal removal is slow. It takes a long time for perceptible wear. Fig (a) Mild abrasion ABRASIVE WEAR
  • 33. The surface appears as though it is polished. A spiral bevel pinion with mild abrasion is shown in Fig. (a) Mild abrasive wear is faced in cement mills, ore grinding mills. Fine dust particles entering the lubricating medium cause three body abrasions. The prior machining marks disappear and surface appears highly polished as shown in Fig.(b). Noticeable wear occurs only over a long time. Sealing improvement and slight pressurization of the gear box with air can reduce the entry of dust particles and decrease this wear. Fig. (b) Mild abrasion ABRASIVE WEAR
  • 34.  Cause: • Foreign particles in the lubricant like dirt, rust, weld spatter or metallic debris can scratch the tooth surface.  Remedy: • Provision of oil filters. • Increasing surface hardness. • Use of high viscosity oils. ABRASIVE WEAR
  • 35. SEVERE ABRASION This wear occurs due to ingress of larger abrasive particles in the lubricating medium and higher concentration of the particles. The particles will plough a series of groove on the surface in the direction of sliding on the gear tooth as seen in the Fig. (c). High rate of wear in this case will quickly reduce the tooth thickness. Thinned tooth may later on fracture leading to total failure. Fig. (c) Severe abrasion ABRASIVE WEAR
  • 36. Miscellaneous tooth-surface deteriorations Burning can result in severe wear and surface deterioration of the previously described types owing to loss of hardness from high temperatures. Remedy:  To reduce friction, look first to the lubricant.  Extreme pressure lubricants will eliminate gear-tooth burning.
  • 37. Corrosive wear is due to the chemical action of the lubricating oil or the additives. Tooth is roughened due to wear and can be seen in the Fig.(d1). Chemical wear of flank of internal gear caused by acidic lubricant is shown in Fig. (d2) (d1) (d2) Fig. d Corrosive wear CORROSIVE WEAR
  • 38.  Cause: Corrosive of the tooth is caused by corrosive elements such as • Extreme pressure additives present in lubricating oils. • Foreign materials.  Remedies: • Providing complete enclosure for the gears free from external contamination. • Selecting proper additives. • Replacing the lubricating oil at regular intervals. CORROSIVE WEAR
  • 39. CONCLUSION Maintenance of gear drives involves proper selection, proper installation, proper loading of the unit,proper lubrication, and periodic inspection. Metallic gears have tremendous service life when properlyused and cared for.