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A gear is a toothed mechanical element that transmits motion and torque through contact with another gear or a rack and pinion. The teeth maintain a prescribed relation between the motions: unlike a smooth friction drive, the ideal gear ratio is set by geometry and tooth counts. The gear pitch circle supplies an imaginary rolling geometry for describing that relation; it is not the circle through the tooth tips.^[ref]

For two external gears on fixed parallel axes, let $N_1,N_2$ be their tooth counts and let signed angular velocities ${\omega }_1,{\omega }_2$ use the same orientation. Each tooth on one gear must pass a tooth space on the other, so counting tooth passages givesThus a 20-tooth input driving a 40-tooth output makes the output turn half as fast in the opposite direction. An input of $1200$ revolutions per minute gives an output of $600$ revolutions per minute in magnitude. These signs describe an external pair; a rack and pinion instead converts rotation into translation.

The useful trade is between angular speed and torque. In an ideal steady transmission, conservation of energy equates input and output power, $|{\tau }_1{\omega }_1|=|{\tau }_2{\omega }_2|$. The same 20-tooth/40-tooth pair therefore turns an input torque of $2\mathrm{N}\mathrm{m}$ into an output torque of $4\mathrm{N}\mathrm{m}$ while halving angular speed. This does not create energy: more torque accompanies less angular displacement per input revolution. Real gears dissipate energy through friction, and backlash permits a small lost motion on reversal; tooth strength and bearings, rather than the gear ratio alone, determine allowable load.

The gear path of recess is the part of the active gear path of contact followed after passing the gear pitch point, in the stated driving direction. For a standard external involute pair driven by gear1, contact ends at the driving gear's tip circle when that tip bounds the usable profile. The recess length lies on the gear line of action; it is not an arc of the gear pitch circle.^[ref]

Use driving-gear tip radius $r_{a1}$, base radius $r_{b1}$, operating radius $r_{w1}$ and operating pressure angle ${\alpha }_w$. The base-circle tangent triangle givesFor a standard module2,20/40-tooth pair at60mm separation and20degree reference angle, $r_{a1}=22\mathrm{mm}$, $r_{w1}=20\mathrm{mm}$ and $r_{b1}=20\cos 20{}^{\circ }\mathrm{mm}$ yield $L_r\approx 4.5960\mathrm{mm}$. The corresponding gear path of approach is about5.0586mm, so the pitch point does not bisect the active contact interval.

At driving angular velocity $50rad/s$, the contact-location speed is $u_b=|{\omega }_1|r_{b1}\approx 0.93969m/s$. Recess therefore lasts about4.891ms. Adding approach gives gear contact duration $T\approx 10.274\mathrm{ms}$. Tooth-passage frequency is $20(50)/(2\pi )\approx 159.155\mathrm{Hz}$, so $T{f}_m\approx 1.6352$, agreeing with the transverse gear contact ratio calculated as active length divided by gear base pitch.

A shorter usable driving flank reduces recess and can change gear sliding-friction loss, because sliding grows with distance from the pitch point. The tip-circle formula alone cannot describe profile modifications or an interfering contact. The geometry and direction must be specified before applying the approach/recess labels.

A gear pitch circle is an imaginary circle used to represent the motion or reference geometry of a gear. A useful distinction is between the gear reference circle, specified for an individual gear, and the operating pitch circle, determined for a meshing pair. The terminology entry in KHK Gear Nomenclature calls the latter the intermeshing pitch circle and also uses the name working pitch circle.^[ref]

For an external pair with fixed axes and constant gear ratio, imagine two operating pitch circles in contact and rolling without slipping. If their radii are $r_1,r_2$ and their axis separation is $a$, their geometry and signed angular velocities obeyThe last equality follows by matching the gear ratio to tooth counts $N_1,N_2$. It is an ideal kinematic construction: the imaginary circles themselves are not physical rims carrying the contact force.

For standard unshifted straight-tooth gears at their standard axis separation, the gear reference circles coincide with the operating pitch circles. The gear module $m$ specifies reference diameter $d=mN$. With $m=2\mathrm{mm}$ and tooth counts 20 and 40, the reference diameters are $40\mathrm{mm}$ and $80\mathrm{mm}$, giving reference radii $20\mathrm{mm}$ and $40\mathrm{mm}$ and standard separation $60\mathrm{mm}$. The reference diameters differ from the larger tooth-tip diameters. If a compatible pair is operated at another axis separation, its gear reference circles remain properties of the individual gears, while its operating pitch circles must fit the new separation and the same tooth-count ratio. This is why an unspecified “pitch diameter” should not silently mix reference geometry with operating geometry.^[ref]

A rack and pinion is a meshing gear pair that converts between rotation and straight-line motion. The pinion is the circular gear and the rack has teeth along a straight path. The ideal motion is described using the gear pitch circle, rather than the outer tips of the teeth. Manufacturer diagrams compare rack travel over one full pinion revolution and show how tooth spacing affects that travel.^[ref]

For a fixed pinion axis and a guided rack, let $r$ be the pitch-circle radius and choose consistent positive directions. With angular displacement $\theta$ in radians,where $\omega$ and $\alpha$ are angular velocity and angular acceleration. For an original example, $r=20\mathrm{mm}$ and a quarter-turn give $x=10\pi \mathrm{mm}\simeq 31.4\mathrm{mm}$. A rotation rate of2revolutions per second gives $v=80\pi \mathrm{mm}{\mathrm{s}}^{-1}\simeq 251\mathrm{mm}{\mathrm{s}}^{-1}$.

Ideal lossless work transfer also givesThus a1newton-metre torque at the same20millimetre pitch radius corresponds to50newtons of tangential rack force. This is a kinematic and energetic model; it omits tooth deformation and friction. Backlash makes reversal especially important: a small rotation can take up clearance before the rack moves. The manufacturer's catalogue explicitly describes backlash adjustment through mounting geometry.^[ref]

In a flywheel-based inerter, a rack and pinion makes relative terminal translation rotate the flywheel. The motion conversion then changes the apparent mechanical inertance without requiring the translating assembly to have that same physical mass.