Gears play an essential role in various mechanical applications, from small machines to large industrial machinery. The automotive industry is one of the areas where gears are extensively used, where they play a vital role in transmitting power from the engine to the wheels. The design of a gear is critical as it affects the performance and efficiency of the system. In this article, we will discuss the design process of a gear with 105 teeth, a pressure degree of 20 degrees, and a module of 2, which is used in an automotive application.
The gear design process began with the measurement of an actual gear that had a broken tooth. Using a measurement tool, the dimensions of the gear were taken, and a sketch was made in Fusion 360 software. Once the sketch was made, the gear tool in Fusion 360 was used to create a 3D model of the gear.
The gear has 105 teeth, and the pressure degree is set to the standard 20 degrees. The module is set to 2, and the gear thickness is 10 mm. The gear has another gear built inside, which has 14 teeth. The internal gear diameter is 32.2 mm.
The gear design process involved several steps, including designing the tooth profile, calculating the dimensions, and creating the 3D model. The tooth profile was designed using the involute gear profile, which is a standard gear profile used in most gear designs. The involute profile ensures smooth and efficient power transmission between gears.
To calculate the dimensions of the gear, various formulas were used, including the pitch diameter, addendum, dedendum, and clearance. The pitch diameter is the diameter of the gear where the teeth are located. The addendum is the distance between the pitch circle and the top of the tooth, while the dedendum is the distance between the pitch circle and the bottom of the tooth. The clearance is the space between the teeth of the gear and the teeth of the mating gear.
The circular pitch of a gear refers to the distance between corresponding points on adjacent teeth of a gear, measured along the pitch circle. It is denoted by the symbol ‘p’ and is usually expressed in millimetres or inches.
The circular pitch is calculated by dividing the circumference of the pitch circle by the number of teeth on the gear:
p = πd/N
- p is the circular pitch
- d is the pitch diameter of the gear
- N is the number of teeth on the gear
- π is the mathematical constant pi (approximately equal to 3.14159)
Circular pitch is an important parameter in gear design and is used to determine other key dimensions, such as the module, addendum, and dedendum of the gear. It also affects the gear’s tooth strength, backlash, and meshing characteristics.
Once the dimensions were calculated, the 3D model of the gear was created using the gear tool in Fusion 360. The gear tool allowed for the easy and accurate creation of the gear with the specified dimensions and tooth profile. The internal gear with 14 teeth was also created using the gear tool and placed inside the larger gear.
The design of a gear is critical to the performance and efficiency of a mechanical system. In this article, we discussed the design process of a gear with 105 teeth, a pressure degree of 20 degrees, and a module of 2, which is used in an automotive application. The design process involved measuring an actual gear, designing the tooth profile, calculating the dimensions, and creating the 3D model using Fusion 360 software. The final product is a gear with precise dimensions and a smooth involute tooth profile, ensuring efficient power transmission in automotive applications.