The updated and improved second edition of Direct Gear Design details a nonstandard gear design approach that makes it possible to significantly improve gear drive performance. Providing engineers with gear design solutions beyond standard limits, this book delivers engineers with practical and innovative solutions to optimize gearing technologies.
The majority of modern gears are over-standardized, not allowing gear design engineers to see possible gear design solutions outside of standard limits. The book explores opportunities to improve and optimize gears beyond these limitations. The method of Direct Gear Design has been proven to maximise gear drive performance, increase transmission load capacity and efficiency, and reduce size and weight. Discussing the use of gears made from powder metal and plastic, the book surveys gear manufacture and makes use of extensive references to encourage further exploration of gear design innovation. Additionally, the book provides an overview of manufacturing technologies and traditional gear design, as well as covering topics such as asymmetric gears, tolerance selection and measurement methods of custom gears.
Written accessibly, with a focus on practical examples, this fully updated edition will serve as a guidebook for all professionals exploring high-performance gearing system technologies.
Table of Contents
1. Historical Overview 1.1. Origin of Direct Gear Design 1.2. Design Based on Gear Rack Generating Technology 1.3. Gear Design without Rack Generating 1.4. Gears with Asymmetric Teeth 2. Macrogeometry of Involute Gears 2.1 Involute of Circle and Involute Function 2.2 Involute Gear Tooth Parameters 2.2.1 Symmetric Gear Tooth 2.2.2 Asymmetric Gear Tooth 2.3 Gear Mesh Characteristics 2.3.1 Symmetric Gearing 2.3.2 Asymmetric Gearing 2.3.3 Helical Gearing Characteristics 2.4 Pitch Factor Analysis 2.5 Application of Direct Gear Design for Different Types of Involute Gears 3 Area of Existence of Involute Gears 3.1 Area of Existence Construction Conditions 3.2 Pressure Angle Isograms 3.2.1 Symmetric tooth gears 3.2.2 Asymmetric tooth gears 3.3 Transverse Contact Ratio Isograms 3.3.1 Symmetric tooth gears 3.3.2 Asymmetric tooth gears 3.4 Overlap Ratio Isograms 3.5 Interference Isograms 3.5.1 Symmetric tooth gears 3.5.2 Asymmetric tooth gears 3.6 Pitch Point Location Isograms 3.6.1 Symmetric tooth gears 3.6.2 Asymmetric tooth gears 3.7 Performance Parameters’ Isograms 3.8 Area of Existence and Gear Tooth Profiles 3.9 Area of Existence and Asymmetry Factors 3.10 Area of Existence and Relative Tooth Tip thicknesses 3.11 Area of Existence and Numbers of Teeth 3.12 Area of Existence and Pitch Factors 3.13 Application of Area of Existence 4 Involute Gearing Limits 4.1 Numbers of Teeth 4.1.1 Symmetric Tooth Gears 4.1.2 Asymmetric Tooth Gears 4.2 Pressure Angle 4.3 Contact Ratio 4.3.1 Symmetric Tooth Gears 4.3.2 Asymmetric Tooth Gears 4.4 Practical range of involute gear parameters 5 Gear Geometry Optimization 5.1 Tooth Macrogeometry 5.1.1 Involute Flank Profile 5.1.2 Tooth Root Fillet Profile 5.1.3 Root Stress Balance 5.2 Tooth Microgeometry 5.2.1 Tooth Flank Modification 5.2.2 Tooth Lead Crowning 6 Stress Analysis and Gear Rating 6.1 Stress Definition 6.2 Gear Rating 6.2.1 Spur Gears 6.2.2 Helical Gears 7 Plastic and Powder Metal Gear Design Specifics 7.1 Gears Plastic Gears 7.2 Powder Metal 8 Tolerancing and Tolerance Analysis 8.1 Gear Specification 8.2 Accuracy Selection 8.3 Tolerance Analysis 9 Gear Manufacturing Essentials 9.1 Fabrication Technologies and Tooling 9.1.1 Gear Machining 9.1.2 Gear Forming 9.1.3 Additive gear technologies 9.2 Gear Measurement 9.2.1 Measurement over (between) Balls or Pins 9.2.2 Composite Gear Inspection 9.2.3 Elemental Gear Inspection 10 Traditional vs Direct Gear Design 10.1 Analytical Comparison 10.2 Experimental Comparison 10.3 Design Method Selection 11 Direct Gear Design Applications 11.1 Speed Boat Gearbox 11.2 Turboprop Engine Gearbox 11.3 Modernization of Helicopter Gearbox Epilogue References Index
Alexander L. Kapelevich is a noted expert in the design and manufacture of gears and gearing systems, with over forty years' experince in the field. He received his M.S. degree from the Moscow Aviation Insitute, and his Ph.D. from the Moscow State Technical University. Dr. Kapelevich worked in the Russian aviation industry following his graduation, working in research and development, software development, testing, and failure investigation. He relocated to the United States in 1994, and developed Direct Gear [email protected], a well-known design approach, and the subject of his book, Direct Gear Design, first published in 2012 by CRC Press. Currently Dr. Kapelevich works as a gear design consultant for AKGears, LLC. He is a member of AGMA (the American Gear Manufacturers Association).