Machine Design LAB
Gear Box Design
Problem Definition
Sachin Dhavane
S P DHAVANE Mechanical MIT AOE
Gear Box Design
Problem Definition
1.What is Application ?
2.What are Operating Parameters ?
3.Which Type Of Gearbox to be Selected ?
S P DHAVANE Mechanical MIT AOE
Gear Box Design
1.What is Application ?
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Gear Box Design
1.Where is Gearbox in That Application ?
Courtesy : NORD DRIVE SYSTEMS
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Gear Box Design
2.Operating Parameters Gearbox ?
What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed
What is Max. Load to be Handled by Conveyor ..?
πDN
V
60
2πNT
P
60
S P DHAVANE Mechanical MIT AOE
Gear Box Design
2.Operating Parameters Gearbox ?
What is Speed / Velocity Requirements of Conveyor Belt ..? 1. O/P Speed
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Gear Box Design
Input Power =?
2.Operating Parameters Gearbox ?
I/P Speed =?
3 HP PINION
Input Power
I/P Speed
1440 RPM GEAR +PINION= GEAR PAIR
GEAR
Speed Reducers
1. O/P Speed 200 RPM
2. Power Required. 2.8 HP
S P DHAVANE Mechanical MIT AOE
Gear Box Design
How Many Stages Are Required ?
3.Which Type Of Gearbox to be Selected ?
Which Gears Are to be Used in Each Stage.?
Layout
Spur Gears
Spur Gears Helical Gears Helical Gears
Bevel Gears
Parallel Shaft Parallel +Perpendicular Shaft
S P DHAVANE Mechanical MIT AOE
Gear Box Design
Selection of Type of Gear
Type of Shaft layout Speed Input Speed and Cost
gear reduction Power to be
transmitted
Spur Parallel 6:1 (10:1) Low and medium Cheape
speed st
Helical Parallel 6:1 (10:1) High speed power Costlier
transmission Spur Gears Helical Gears
Bevel Perpendicular 1:1 (3:1) Low speed Costlier
Worm Perpendicular 60:1 (100:1) Low speed Costlier
and non-intersecting
Bevel Gears
Worm & Worm Wheel Gears
Sachin Dhavane Mech Engg MIT AOE
Gear Box Design
3.Which Type Of Gearbox to be Selected ? Which Gears Are to be Used in Each Stage.?
Input Power 3 HP
How Many Stages Are Required ?
I/P Speed 1440 RPM
Total Speed Reduction Ration of Gearbox ?
O/P Speed 200 RPM I Stage
Speed Reduction Ration of Each Stage ?
1440 RPM
1440
i 2 i ' For 2 Stages i 2 7.2 2.68
i
'
200
i 3 i ' For 3 Stages 2.68 2.68 7.2 II Stage
i
'
or 7.2 : 1 200 RPM
I Stage II Stage 1
In a Multi Stage Gearbox , Single Stage Should Not Exceed 6:1
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Problem Definition
Gear Box Design
1.What is Application ? Airport Luggage Conveyors
Input Power 3 HP
2.What are Operating Parameters ?
I/P Speed 1440 RPM
O/P Speed 200 RPM
3.Which Type Of Gearbox to be Selected ? Two Stage Helical Bevel
Problem Statement: Design a Two stage Helical-Bevel Gearbox which is used in
Airport Luggage Conveyors where Input Speed is 1440 rpm , Output Speed is 200
rpm and Power requirement is 3 HP .
S P DHAVANE Mechanical MIT AOE
Gear Box Design
S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK
Gear Box Design
S P DHAVANE Mechanical MIT AOE Courtesy : PSG DESIGN DATA BOOK
Lab 5
Machine Design LAB
Gear Box Design
Material Selection & Force Analysis
Sachin Dhavane Amit Belvekar-Patil
S P DHAVANE Mechanical MIT AOE
EXTRA READING SECTION
Page Number 671 in V B BHANDARI (VBB)
Type of Shaft layout Speed Input Speed Cost
gear reduction and
Power to be
transmitted
Spur Parallel 6:1 (10:1) Low and Cheap
medium speed est
Helical Parallel 6:1 (10:1) High speed Costlie
power r
transmission
Bevel 1:1 (3:1) Low speed Costlie
Perpendicular r
Worm 60:1 (100:1) Low speed Costlie
Perpendicular r
and non-
intersecting
S P DHAVANE Mechanical MIT AOE
Gear Box Design Selection Of Material for Gears
Selection of Material is based on Gear Ratio in each stage
Page Number 8.4 in Design Data Book (DDB)
i 2 7.2 2.68
Courtesy : PSG DESIGN DATA BOOK
Gear Box Design Selection Of Material for Gears
i 2 7.2 2.68 <4
# Select Material for Pinion is C45 & For Wheel C35Mn75
Courtesy : PSG DESIGN DATA BOOK
Gear Box Design Selection Of Material for Gears
Find
# Find Properties of C45 & C35Mn75 Sut: Ultimate Tensile Strength,
Syt: Yeild Strength,
Page Number 1.10-1.12 in Design Data Book (DDB)
BHN: Brienel Hardness Number
For C45
Sut 700 N / mm2
Syt 380 N / mm2
Courtesy : PSG DESIGN DATA BOOK
Gear Box Design Selection Of Material for Gears
# Find Properties of C45 & C35Mn75
Page Number 1.10-1.12 in Design Data Book (DDB)
For C35Mn75
Sut 700 N / mm2
Syt 400 N / mm2
Courtesy : PSG DESIGN DATA BOOK
Gear Box Design Selection Of Material for Gears
# Find Properties of C45 & C35Mn75 Find Hardness
Page Number 1.9 & 1.13 in Design Data Book (DDB)
300 For C35Mn75
330 For C45
Courtesy : PSG DESIGN DATA BOOK
Gear Box Design Page Number 8.4 in Design Data Book (DDB)
Courtesy : PSG DESIGN DATA BOOK
Rough Force Analysis
I Stage
1440 RPM
II Stage
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Force Analysis
Sachin Dhavane Mech Engg MIT AOE
Force Analysis
DRIVING
P
Ft
V
d p n p
V
60 x 1000
d g n g
V
60 x 1000 DRIVEN
Fr Ft tan φ
F FT2 FR2
Sachin Dhavane Mech Engg MIT AOE
Force Analysis
Sachin Dhavane Mech Engg MIT AOE
Force analysis of Helical gear Page Number 699 in V B BHANDARI (VBB)
øn Fr Fa
øt Ѱ
Ft 900
900 Ѱ
Mr. Sachin Dhavane Assistant Professor Mech Engg
Forces on gear tooth
Fn
Fr
øn
øt Ѱ
Fa
Ft
Mr. Sachin Dhavane Assistant Professor Mech Engg
EXTRA READING SECTION
Page Number 698 in V B BHANDARI (VBB)
Page Number 707 V B BHANDARI (VBB)
S P DHAVANE Mechanical MIT AOE
Magnitude of forces in Helical gear
Tangential force Ft Radial force Fr
Ft tan n
Ft
P( KW ) Fr Ft tan t
V cos
Tp Tg
Ft
dp dg Axial force Fa Fa Ft tan
2 2
Resultant force F
F Ft Fr Fa
2 2 2
Mr. Sachin Dhavane Assistant Professor Mech Engg
Direction of Axial force in Helical gear
Axial component in helical gear is undesirable
Depends upon
Whether the gear under consideration is driving or driven gear
The hand of helix
Direction of gear
To find the direction of axial component
Apply hand rule to the driving gear
RH helix
Mr. Sachin Dhavane Assistant Professor Mech Engg Driving gear
Force analysis
Mr. Sachin Dhavane Assistant Professor Mech Engg
S P DHAVANE Mechanical MIT AOE
S P DHAVANE Mechanical MIT AOE
Page Number 8.56 in Design Data Book (DDB)
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Lab 6
Machine Design LAB
Gear Box Design
Gear Design
Sachin Dhavane
S P DHAVANE Mechanical MIT AOE
STEP 1 Beam Strength of a Spur Gear Tooth Spur Gear
Step 1: Beam Strength of teeth using Lewis Weaker of Gear & Pinion in bending
equation
Pinion
F m.b. b .Y
b Gear
( Sut ) p ( Sut ) g
bp bg
3 3
2.87 2.87
Yp 0.484 Yg 0.484
Zp Zg
bp .Yp bg .Yg
bp .Yp
< bg .Yg Pinion is weaker in bending Fb m.b. bp .Yp
bp .Yp
> bg .Yg Gear is weaker in bending Fb m.b. bg .Yg
STEP 2 Wear Strength of a Spur Gear Tooth Spur Gear
Step 2: Wear strength Maximum tangential load gear tooth can take without wear/pitting failure
Fw d pb.Q.K
dp= Pitch Circle Diameter of pinion d p m.Z p
in mm
2Z g
Q=Ratio factor for external gear Q
(Z g Z p )
pair
2
K= load stress factor N/mm2 BHN When Pinion & Gear made with Steel- Steel
K 0.16
100
2
BHN
K 0.18 When Pinion & Gear made with Steel- Cast Iron
100
2
BHN When Pinion & Gear made with Cast Iron- Cast Iron
K 0.21
100
Q=Ratio factor for Internal gear pair 2Z g
Q
(Z g Z p )
STEP 3 Spur Gear
Beam Strength V/s Wear Strength
Fb σ b bmY Fw d pb.Q.K
Fb < Fw Gear Pair is weaker in Bending
Fb > Fw Gear Pair is weaker in Pitting
Sachin Dhavane Mech Engg MIT AOE
STEP 4 Spur Gear
Ft Tangential Force
Ft max Max Tangential Force
Feff Total Max Tangential Force
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STEP 4 Spur Gear
Maximum Tangential Load F tmax :
Maximum Tangential Load (Ftmax ) is given by
Ft max ka K m Ft
Where Ka is Service / Application / Overload factor
Ks Depends upon application
Driving and Driven elements Compressor
Max Torque
Ka
Rated Torque
Motor
Sachin Dhavane Mech Engg MIT AOE
Ka is Service / Application / Overload factor Spur Gear
Sachin Dhavane Mech Engg MIT AOE
Spur Gear
Load Distribution Factor/ Load concentration Factor Km
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Spur Gear
Calculation Dynamic load (Fd)
Preliminary Estimation Precise Estimation
STEP 4 STEP 5
Sachin Dhavane Mech Engg MIT AOE
STEP 4 Preliminary Estimation By Velocity factor Kv: Spur Gear
Ft max K a Ft K m
Feff
kV KV
3 m 6 m
KV V 10 KV V 20
3 V s 6 V s
3.6 m
KV 20 V 25
3.6 V s
Module m
5.6 m
KV 25 V 30
5.6 V s
Sachin Dhavane Mech Engg MIT AOE
STEP 5 Precise Estimation By Buckinghams Equation Fd:
Spur Gear
• According to Buckingham Approach Fd is given by
21V bC Ft max
Fd
21V bC Ft max
ke E p Eg
C ke
1 E p Eg C =Deformation factor
1
E p Eg
K is constant, depends on tooth
E =modulus of Elasticity form
K=0.107 -14.50
K =tooth Form factor
K=0.111 - 200 Full depth
e = Combined Tooth Error K=0.115 - 200 stub
Sachin Dhavane Mech Engg MIT AOE
STEP 5 C =Deformation factor Spur Gear
ke E p Eg
C ke e = Combined Tooth Error
1 E p Eg
1
E p Eg e = ep + eg
Sachin Dhavane Mech Engg MIT AOE
Spur Gear
STEP 5
e = ep + eg
Sachin Dhavane Mech Engg MIT AOE
STEP 5 Spur Gear
Effective Load on Gear Tooth
Actual Load on gear tooth to transmit power
Tangential Load + Dynamic Load
Effective Load Feff
Tangential Load Dynamic Load
Ftmax Fd
Feff Ftmax Fd
Sachin Dhavane Mech Engg MIT AOE
STEP 6 Design Check Check the Safety of gear Pair Spur Gear
Check the Safety Against bending failure
In order to avoid the bending failure Fb > Feff
By Considering the FOS Fb N f Feff
In order to avoid the Pitting failure Fw > Feff
By Considering the FOS Fw N f Feff
Sachin Dhavane Mech Engg MIT AOE
Gear Design Spur Gear
STEP 1 Beam Strength
Helical Gear
STEP 2 Wear Strength
Bevel Gear
STEP 3 Beam Strength V/s Wear Strength
STEP 4 Preliminary Estimation By Velocity factor Kv:
STEP 5 Precise Estimation By Buckinghams Equation Fd:
STEP 6 Design Check
Sachin Dhavane Mech Engg MIT AOE
GearBox Design
Helical -Spur Gearbox
STEP 1 Gear Pair for I & II Stage
Helical -Helical Gearbox
STEP 2 Shaft & Key Design (I , II , III Shaft)
Helical -Bevel Gearbox
STEP 3 Bearing Selection for I , II, III Shafts
Bevel-Helical Gearbox
STEP 4 Casing Design (Upper Casing + Lower Casing)
STEP 5 Selection of Standard Parts in Gearbox
STEP 6 Final Drawing Preparation
Sachin Dhavane Mech Engg MIT AOE
Gear Box Design
Problem Definition Helical -Bevel Gearbox
1.What is Application ? Airport Luggage Conveyors
Input Power 3 HP
2.What are Operating Parameters ?
I/P Speed 1440 RPM
O/P Speed 200 RPM
3.Which Type Of Gearbox to be Selected ? Two Stage Helical Bevel
Problem Statement: Design a Two stage Helical-Bevel Gearbox which is used in
Airport Luggage Conveyors where Input Speed is 1440 rpm , Output Speed is 200
rpm and Power requirement is 3 HP .
S P DHAVANE Mechanical MIT AOE
Gear Box Design
I Stage
II Stage
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Sample Problem For Gears
A spur pinion having 21 teeth to be made of plain carbon steel 55C8 ( Sut=720 N/mm2) is to mesh
with a gear to be made of plain carbon steel 40C8 ( Sut=580 N/mm2).The gear pair is required to
transmit 22 KW power from an IC engine running at 1000 rpm to a machine running at 300 rpm.
The starting torque required is 200% of rated torque while the load distribution factor is 1.5. The
factor of safety required is 1.5. The face width is ten times module and tooth system is 20 full
depth involute. The gears are to be machined to meet the specifications of grade 6. The gear and
pinion are to be case hardened to 400 BHN and 450 BHN resp. The deformation factor C for gear
pair is 11500e N/mm. Design the gear pair by using dynamic factor Kv= 6/6+v and the
buckingham’s equation for dynamic load.
Sachin Dhavane Mech Engg MIT AOE
STEP 1 Gear Pair for I & II Stage Input Power I/P Speed O/P Speed
Power Ka FOS Kv
Km
Gear Pinion
Material Gear Ratio G Material C Deformation or Dynamicfactor
e = Combined Tooth Error
Sut gear Sut pinion
Facewidth & Module Relation
S yt Gear
S yt pinion
Type of standard Tooth System
BHNgear BHNpinion
Grade to which the Gears are Manufactured
Zg Zp
Helix Angle in Case of Helical Gears
Ng Np
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Ka is Service / Application / Overload factor Page Number 707 in V B BHANDARI (VBB)
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Kv Velocity Factor Spur Gear Helical Gear
Page Number 702 in V B BHANDARI (VBB)
Bevel Gear
Page Number 676 in V B BHANDARI (VBB)
Page Number 723 in V B BHANDARI (VBB)
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Type of standard Tooth System
Zp
Zp
Zp
Page Number 653-654 in V B BHANDARI (VBB)
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C Deformation or Dynamicfactor
Page Number 677 in V B BHANDARI (VBB)
Page Number 8.53 in PSG DESIGN DATA BOOK (DDB)
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C Deformation or Dynamicfactor Page Number 680 in V B BHANDARI (VBB)
e = Combined Tooth Error
ke E p Eg
C ke
1 E p Eg
1
E p Eg
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Helix Angle in Case of Helical Gears
Page Number 707 in V B BHANDARI (VBB)
S P DHAVANE Mechanical MIT AOE
FOS
Page Number 707 in PSG DESIGN DATA BOOK (DDB)
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Lab 6
Machine Design LAB
Gear Box Design
Shaft & Key Design
Sachin Dhavane
S P DHAVANE Mechanical MIT AOE
Gear Box Design
Input Shafts
Output Shaft
Intermediate Shafts
S P DHAVANE Mechanical MIT AOE Courtesy : Pg No 8.59 PSG DESIGN DATA BOOK
Gear Box Design
Output Shaft
Input Shafts
Intermediate Shafts
S P DHAVANE Mechanical MIT AOE Courtesy : Pg No 8.61 PSG DESIGN DATA BOOK
Problem : The layout of an intermediate shaft of a gear box which supports
two gears B and C. The PCD (pitch circle diameter) of gears B and C are 800
mm and 500 mm resp. The shaft is made of alloy steel steel (Sut= 720 Mpa
and Syt=570 Mpa. Design the shaft using A.S.M.E code if Kb=2
Kt=1.5.Assume that the gears are connected to the shaft by means of keys.
Solution: d=69 mm
Prof.Sachin Dhavane Mech Engg Dept
Problem : The transmission shaft supporting a helical gear B and an overhung bevel gear D
is Shown in Fig. The helical gear and bevel gear( at the larger end) have a pitch circle
diameter of 500 mm. Power is transmitted from the helical gear to bevel gear. The gears are
keyed to the shaft. The shaft material has an ultimate tensile strength of 500 N/mm2 and a
yield strength of 340 N/mm2. Determine the shaft diameter using ASME code. Kb=1 Kt=1.5
also find the torsional rigidity of shaft G=80000 N/mm2.
Solution:
Prof.Sachin Dhavane Mech Engg Dept
Design of Shafts ??
Type of Shaft Dimensions MaterialSelection
Solid Shaft d Material Grade
Syt
L
Hollow Shaft
Sut
Spline Shaft
S P DHAVANE Mechanical MIT AOE
S P DHAVANE Mechanical MIT AOE
b
b1
L2
L2 C
B/2
B/2
B B
L2 b c b1 L2
2 2
S P DHAVANE Mechanical MIT AOE
B B
L2 b c b1 L2
2 2
b
b1
L2
L2 C
B/2
B/2
Page Number 8.63 in Design Data Book (DDB)
S P DHAVANE Mechanical MIT AOE
MaterialSelection
Material Grade
Syt
Sut
Page Number 331 in V B BHANDARI (VBB)
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MaterialSelection
Material Grade
Syt
Sut
S P DHAVANE Mechanical MIT AOE
Page Number 1.10 in Design Data Book (DDB)
MaterialSelection
Material Grade
Syt
Sut
For Alloy Steel Properties
Refer Page Number 1.17 to
1.20 in Design Data Book
(DDB)
S P DHAVANE Mechanical MIT AOE
Page Number 1.12 in Design Data Book (DDB)
Page Number 334 in V B BHANDARI (VBB)
S P DHAVANE Mechanical MIT AOE
GearBox Design
Helical -Spur Gearbox
STEP 1 Gear Pair for I & II Stage
Helical -Helical Gearbox
STEP 2 Shaft & Key Design (I , II , III Shaft)
Helical -Bevel Gearbox
STEP 3 Bearing Selection for I , II, III Shafts
Bevel-Helical Gearbox
STEP 4 Casing Design (Upper Casing + Lower Casing)
STEP 5 Selection of Standard Parts in Gearbox
STEP 6 Final Drawing Preparation
Sachin Dhavane Mech Engg MIT AOE
Design of Keys
Prof.Sachin Dhavane Mech Engg Dept
Types of Keys
KEYS
Sunk Keys Saddle keys Tangent keys Splines
1.Rectangular 1.Flat OR
Round
2.Square 2.hollow Kennedy Keys
3.Parallel
4.Gib Headed
5.Feather
6.Woodruff
Prof.Sachin Dhavane Mech Engg Dept
Key Design (I , II , III Shaft)
S P DHAVANE Mechanical MIT AOE
Lab 7
Machine Design LAB
Gear Box Design
Casing Design
S P DHAVANE Mechanical MIT AOE
Gearbox Casing/ Gearbox Housing
The gear housing is a Mechanical Housing that
surrounds the Mechanical components of a gear box.
It provides mechanical Support For The Moving
Components,
Provides Mechanical Protection From The Outside
World for those internal components.
A fluid-tight container to Hold The Lubricant that
bathes those components
S P DHAVANE Mechanical MIT AOE
Types of Gearbox Casing/ Gearbox Housing
TYPE I
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Types of Gearbox Casing/ Gearbox Housing
TYPE II
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Types of Gearbox Casing/ Gearbox Housing
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Gearbox Casing/Housing design
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Gear Box Design
Length
Width
S P DHAVANE Mechanical MIT AOE Courtesy : Pg No 8.59 PSG DESIGN DATA BOOK
B B
L2 b c b1 L2
2 2
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Thickness of Casing
Pg No 10. 14 PSG DESIGN DATA BOOK
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Thickness of Casing
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Material Selection of Casing
S P DHAVANE Mechanical MIT AOE
GearBox Design
Helical -Spur Gearbox
STEP 1 Gear Pair for I & II Stage
Helical -Helical Gearbox
STEP 2 Shaft & Key Design (I , II , III Shaft)
Helical -Bevel Gearbox
STEP 3 Bearing Selection for I , II, III Shafts
Bevel-Helical Gearbox
STEP 4 Casing Design (Upper Casing + Lower Casing)
STEP 5 Selection of Standard Parts in Gearbox
STEP 6 Final Drawing Preparation
Sachin Dhavane Mech Engg MIT AOE
Mr. Sachin Dhavane Mech Engg MITAOE
Mr. Sachin Dhavane Mech Engg MITAOE
Selection Of Bearing Life
Mr. Sachin Dhavane Mech Engg MITAOE
Selection Of Bearing Life
Mr. Sachin Dhavane Mech Engg MITAOE
Bearing Problem for Understanding
An intermediate shaft of a two stage coaxial gearbox receives 10 KW power at 288 rpm
through right hand helical gear and transmits it to the output shaft through the spur pinion.
The PCDs of helical gear and spur pinion are 450 mm and 108 mm resp. The helix angle
and normal pressure angle for helical gear are 23 and 20 resp. The pressure angle for the
spur pinion is 20.The diameters of shaft at bearings A and B are 50 mm and 60 mm resp.
The load factor is 1.8 and expected rating life of bearing is 25000 hours. Select the deep
groove ball bearings at A and B. The Bearings are mounted such that bearing at A takes the
thrust load.
Mr. Sachin Dhavane Mech Engg MITAOE
Mr. Sachin Dhavane Mech Engg MITAOE
Selection Of Bearing From Manufacturers Catalogue
1. Calculate Fr and Fa acting on bearings
2. Determine the shaft diameter on which bearing to be mounted
3.For given Application, selection of proper type of bearing.
4. By trial and error , select the bearing. First begin with extra light
series for known shaft diameter d.
5. From catalogue find Co of selected bearing.
6. Calculate the ratios (Fa / V Fr) and (Fa / Co)
7. Find X and Y based on step 6 from catalogue.
Mr. Sachin Dhavane Mech Engg MITAOE
Selection Of Bearing From Manufacturers Catalogue
8. Select Ka for the application
9. Calculate Pe=(X V Fr+Y Fa) Ka
10. Select the expected life of bearing for given application
and express in million revolutions.
11. Calculate required basic dynamic capacity Cr
12.Check C > Cr .If No then select bearing of next series and
repeat from step 5.
Mr. Sachin Dhavane Mech Engg MITAOE
Standard Parts
Eye bolts
Air Breather
Drain Plug
Fasteners
Circlips
Gaskets or oil Seals
Oil Level Indicator
Dip Stick
Lubrication Oil
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S P DHAVANE Mechanical MIT AOE
Eye bolts
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Drain Plug
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Air Breather
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Gaskets or oil Seals
S P DHAVANE Mechanical MIT AOE
Lubrication Oil
Dip Stick
Oil Level Indicator
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Oil Level Indicator
S P DHAVANE Mechanical MIT AOE
Circlips
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