GEARS

A gear is a component within a transmission device that transmits rotational torque by applying a force to the teeth of another gear or device. A gear is different from a pulley in that a gear is a round wheel that has linkages ("teeth" or "cogs") that mesh with other gear teeth, allowing force to be fully transferred without slippage. Depending on their construction and arrangement, geared devices can transmit forces at different speeds,torques, or in a different direction, from the power source.

The most common situation is for a gear to mesh with another gear, but a gear can mesh with any device having compatible teeth, such as linear moving racks.

The gear's most important feature is that gears of unequal sizes (diameters) can be combined to produce a mechanical advantage, so that the rotational speed and torque of the second gear are different from those of the first. In the context of a particular machine, the term "gear" also refers to one particular arrangement of gears among other arrangements (such as "first gear"). Such arrangements are often given as a ratio, using the number of teeth or gear diameter as units. The term "gear" is also used in non-geared devices that perform equivalent tasks.

The interlocking of the teeth in a pair of meshing gears means that their circumferences necessarily move at the same rate of linear motion (e.g., metres per second, or feet per minute). Since rotational speed (e.g. measured in revolutions per second, revolutions per minute, or radians per second) is proportional to a wheel's circumferential speed divided by its radius, the larger the radius of a gear, the slower will be its rotational speed, when meshed with a gear of given size and speed. The same conclusion can also be reached by a different analytical process: counting teeth. Since the teeth of two meshing gears are locked in a one to one correspondence, when all of the teeth of the smaller gear have passed the point where the gears meet – i.e., when the smaller gear has made one revolution – not all of the teeth of the larger gear will have passed that point – the larger gear will have made less than one revolution. The smaller gear makes more revolutions in a given period of time; it turns faster. The speed ratio is simply the reciprocal ratio of the numbers of teeth on the two gears.

(Speed A * Number of teeth A) = (Speed B * Number of teeth B)

This ratio is known as the gear ratio.

The torque ratio can be determined by considering the force that a tooth of one gear exerts on a tooth of the other gear. Consider two teeth in contact at a point on the line joining the shaft axes of the two gears. In general, the force will have both a radial and a tangential component. The radial component can be ignored: it merely causes a sideways push on the shaft and does not contribute to turning. The tangential component causes turning. The torque is equal to the tangential component of the force times radius. Thus we see that the larger gear experiences greater torque; the smaller gear less. The torque ratio is equal to the ratio of the radii. This is exactly the inverse of the case with the velocity ratio. Higher torque implies lower velocity and vice versa. The fact that the torque ratio is the inverse of the velocity ratio could also be inferred from the law of conservation of energy. Here we have been neglecting the effect of friction on the torque ratio. The velocity ratio is truly given by the tooth or size ratio, but friction will cause the torque ratio to be actually somewhat less than the inverse of the velocity ratio.

In the above discussion mention has been made of the gear "radius". A gear does not have a smooth perimeter so it does not have a radius. However, in a pair of meshing gears, each may be considered to have an effective radius, called the pitch radius. Two smooth circular wheels of radii equal to the pitch radii of two gears would produce the same velocity ratio as the gears. The pitch radius is less than the outside radius of the gear and more than the radius at the base of the teeth.

The point on a gear tooth where it contacts the tooth of the mating gear varies during the time the pair of teeth are engaged; also the direction of force may vary. As a result, the velocity ratio and torque ratio are not necessarily constant during the period of engagement of a pair of teeth. The velocity and torque ratios given at the beginning of this section are the average values during the period of engagement of any pair of teeth. The instantaneous values may vary slightly.

It is in fact possible to choose tooth shapes that will result in the velocity ratio also being absolutely constant – in the short term as well as the long term. In good quality gears this is usually done, since velocity ratio fluctuations cause undue vibration, and put additional stress on the teeth, which can cause tooth breakage under heavy loads at high speed. Constant velocity ratio may also be desirable for precision in instrumentation gearing, clocks and watches. The involute tooth shape is one that results in a constant velocity ratio, and is the most commonly used of such shapes today.