UNDERGRADUATE CEP REPORT
Department of Mechanical Engineering
NED University of Engineering and Technology
Batch: 2022 – 2026
Course: Machine Design
Course code: ME-323
Group Members:
Wania Wasaaf ME-22048
Iraj Kamran ME-22050
Wahab Qazi ME-22071
Syeda Raheen Hasan ME-22318
© NED University of Engineering & Technology. All Rights Reserved – [Spring, 2025]
Table of Contents
CHAPTER 01 INTRODUCTION ............................................................................................................. 1
INTRODUCTION: ................................................................................................................................. 1
OBJECTIVE: .......................................................................................................................................... 1
IMPORTANCE OF GEARBOXES IN INDUSTRIAL APPLICATIONS: ...................................... 1
INDUSTRY DESCRIPTION:................................................................................................................ 1
CHAPTER 02 GEARBOX DESIGN: ....................................................................................................... 2
2.1 GEAR TYPE SELECTION: ............................................................................................................ 2
2.2 CALCULATIONS OF CAPSULE MAKING MACHINE GEARBOX SETUP: ....................... 2
CHAPTER 03 CAD MODULING AND SIMULATION ........................................................................ 9
3.1 INTRODUCTION............................................................................................................................. 9
3.2 Finite Element Analysis In ANSYS ................................................................................................. 9
3.2.1 SIMULATION SETUP.............................................................................................................. 9
3.3 CAD MODEL: ................................................................................................................................ 10
CHAPTER 04 GEAR BOX SELECTION.............................................................................................. 12
4.1 INTRODUCTION........................................................................................................................... 12
4.2 COMMERCIAL GEARBOX SELECTION: ............................................................................... 12
4.3 SELECTION JUSTIFICATION ................................................................................................... 12
4.4 CONCLUSION: .............................................................................................................................. 13
CHAPTER 05 DISCUSSION: ................................................................................................................. 14
5.1 DISCUSSIONS ................................................................................................................................ 14
5.2 PERFORMANCE & SUITABILITY COMPARISON:.............................................................. 15
5.3 VALUE OF BOTH APPROACHES:............................................................................................ 15
CHAPTER 06 CONCLUSION ................................................................................................................ 16
6.1 SUMMARY: .................................................................................................................................... 16
Author’s Declaration
We declare that we are the sole authors of this project. It is the actual copy of the project that
was accepted by our advisor(s) including any necessary revisions. We also grant NED University
of Engineering and Technology permission to reproduce and distribute electronic or paper
copies of this project.
Signature Signature Signature Signature
................................. ................................. ................................. .................................
[Wania Wasaf] [Iraj Kamran] [Wahab Qazi] [Raheen Hasan]
[ME-22048] [ME-22050] [ME-22071] [ME-22318]
wasaf4504532@cloud. kamran4504123@cloud. wahab4503912@clou hasan4502008@cloud.
neduet.edu.pk neduet.edu.pk d.neduet.edu.pk neduet.edu.pk
Statement of Contributions
The completion of this project was a collaborative effort among all team members, each
contributing to distinct and essential aspects in the gearbox designing:
1. Wahab Qazi conducted the site visit analysis, collected technical data from SOIS Life
Sciences, and contributed to the gearbox design calculations.
2. Wania Wasaf led the gear train calculations, including torque distribution and selected
the commercial gearbox from manufacturer catalogs.
3. Raheen Hasan developed the CAD models of the gearbox using SolidWorks and
performed the stress analysis for gear validation.
4. Iraj Kamran researched and performed comparative analysis, and finalized the
formatting and compilation of the report.
CHAPTER 01 INTRODUCTION
INTRODUCTION:
Gearboxes play a critical role in various industrial applications by transmitting mechanical power
efficiently and reliably. They serve to adjust speed and torque between driving and driven
equipment, ensuring optimal performance, energy efficiency, and mechanical stability. Whether
in conveyor systems, wind turbines, or heavy machinery, the appropriate design and selection of a
gearbox significantly impacts operational safety, productivity, and equipment lifespan.
OBJECTIVE:
The objective of this report is to design a custom gear train tailored for a specific industrial
application and to select a compatible, commercially available gearbox from a manufacturer’s
catalog. The design process will involve choosing a suitable gear type, calculating essential
parameters such as gear ratio, number of teeth, and module, and validating the design using
established engineering standards and simulation tools. Subsequently, the selected gearbox from
the catalog will be evaluated to ensure it meets the technical and operational requirements of the
application.
IMPORTANCE OF GEARBOXES IN INDUSTRIAL APPLICATIONS:
Gearboxes are essential mechanical components in industrial systems where controlled speed and
torque are required. They allow machines to operate within their optimal performance range by
converting the high-speed input from motors into the desired speed and torque for the application.
In industries such as manufacturing, mining, material handling, and power generation, gearboxes
enhance system efficiency, reduce mechanical stress, and enable the smooth and safe operation of
heavy-duty equipment. Their ability to handle varying load conditions while maintaining precision
and reliability makes them indispensable in ensuring the productivity, durability, and operational
integrity of industrial machinery.
INDUSTRY DESCRIPTION:
Our group visited SOIS Life Sciences, a renowned nutraceutical manufacturer in Pakistan with a
state-of-the-art, GMP-compliant facility. With over 14 years of experience, SOIS has
established itself as one of the largest producers of specialized nutraceutical products in the
country. The company supplies high-quality formulations to leading pharmaceutical brands
including Helix Pharma, MaxiTech Pharma, Horizon Pharma, XL Health Care, and Scilife
Pharma.
The facility operates under stringent quality standards and features advanced production systems
for capsule manufacturing, packaging, and quality control. The visit provided valuable technical
insights into the machinery involved in capsule production particularly the mechanical and
operational demands of capsule-making machines which served as the foundation for our gearbox
design project.
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CHAPTER 02 GEARBOX DESIGN:
2.1 GEAR TYPE SELECTION:
For the gearbox system of the capsule making machine, spur gears are selected. Spur gears are
the most common and cost-effective gear type, offering simplicity in design and ease of
manufacturing. In this application, the gear train is mounted on parallel shafts and operates at
moderate speeds, making spur gears a practical choice. While helical gears are quieter and handle
higher loads, the capsule machine prioritizes mechanical simplicity, precise timing, and easy
maintenance all strengths of spur gears.
The system uses a multi-stage spur gear train, which provides stepwise speed reduction and
torque amplification suited for the delicate and synchronized operations of capsule filling, forming,
and sealing.
2.2 CALCULATIONS OF CAPSULE MAKING MACHINE GEARBOX SETUP:
System Setup Description:
Motor (1.5 HP, 1400 RPM) connected to:
Large sprocket ( 36 tooth) on motor shaft
Chain drive to a smaller sprocket (18 tooth) mounted on the upper shaft
Upper shaft is attached to:
Gear X (16 tooth, 35 mm OD)
Gear X meshes with Gear A (105 tooth, 201 mm OD)
Gear A drives Gear D (32 tooth, 64 mm OD)
Gear D meshes with Gear C (32 tooth, 64 mm OD)
Gear C meshes with Gear B (65 tooth, 123 mm OD)
Gear B drives the capsule roller.
Pitch of all gears = 3 mm
Tooth Thickness = 3 mm
Module:
Circular Pitch = 2 × Tooth Thickness
Circular Pitch = 2 × 3 = 6 mm
𝑃𝑐
Module = m =
𝜋
6
Module = m = 𝜋 = 1.909 mm
2
Number of teeth:
𝑂𝐷−2 × 𝑚
N= 𝑚
GEAR X:
35 −2 × 1.909
N= = 16 T
1.909
GEAR A:
201 −2 × 1.909
N= = 105 T
1.909
GEAR B:
123 −2 × 1.909
N= = 65 T
1.909
GEAR C:
64 −2 × 1.909
N= = 32 T
1.909
GEAR D:
64 −2 × 1.909
N= = 32 T
1.909
Pitch Diameter:
dp = m × N
GEAR X:
dp = 1.909 × 16 = 30.5 mm
GEAR A:
dp = 1.909 × 105 = 200.5 mm
GEAR B:
dp = 1.909 × 65 = 124.085 mm
GEAR C:
dp = 1.909 × 32 = 61.08 mm
GEAR D:
dp = 1.909 × 32 = 61.08 mm
Power Transmission Calculations:
Motor Output Torque:
9550 × 𝑃
T motor = 𝑅𝑃𝑀
3
9550 ×1.119
T motor = = 7.63 Nm
1400
After Chain Drive (2:1):
RPM upper shaft = 1400 x 2 = 2800 RPM
7.63
T upper shaft = 2 = 3.815 Nm
Simple Gear Train Ratios:
Gear X to Gear A:
105
e1 = 16 = 6.5625
Gear A to Gear D:
32
e2 = 105 = 0.30476
Gear D to Gear C:
32
e3 = 32 = 1
Gear C to Gear B:
65
e4 = 32 = 2.03125
Total Gear Ratio:
e = 6.5625 × 0.30476 × 1 × 2.03125 = 4.06
As e > 1 i.e. gear train is torque multiplier and speed divider
Final RPM:
2800
RPM final = 4.06 = 689.65 RPM
Torque Calculation:
𝟗𝟓𝟓𝟎 × 𝞠
𝑇=
𝞜
Where:
• T = Torque (Nm)
• P = Power (kW)
• N = RPM
9550 is derived from (60 × 1000) / (2π)
4
Step 1: Motor Torque (Direct from power)
Given:
• Power = 1.5 HP = 1.119 kW
• RPM = 1400
𝟗𝟓𝟓𝟎 × 𝟏. 𝟏𝟏𝟗
𝑇𝑚𝑜𝑡𝑜𝑟 = = 𝟕. 𝟔𝟑𝑵𝒎
𝟏𝟒𝟎𝟎
Step 2: After Chain Drive (2:1 Speed Increase, Torque Decrease)
• RPM upper shaft = 1400 × 2 = 2800
Torque upper shaft:
Gear Driving Torque Calculation Torque
Gear Formula (Nm)
X Chain From motor = 3.815 3.815
A X 3.815 × (105 / = 3.815 × 6.5625 25.04
16)
D A 25.04 × (32 / = 25.04 × 0.30476 7.63
105)
C D 7.63 × (32 / = 7.63 7.63
32)
B C 7.63 × (65 / = 7.63 × 2.03125 15.5
32)
𝑇𝑚𝑜𝑡𝑜𝑟
𝑇𝑥 = = 𝟑. 𝟖𝟏𝟓𝑵𝒎
𝟐
This torque will be applied on gear x:
Step 3: Gear Torque Calculations Based on Gear Ratio
𝑁𝑑𝑟𝑖𝑣𝑒𝑛 𝑡𝑒𝑒𝑡ℎ
𝑇𝑑𝑟𝑖𝑣𝑒𝑛 = 𝑇𝑑𝑟𝑖𝑣𝑒𝑟 ×
𝑁𝑑𝑟𝑖𝑣𝑒𝑟 𝑡𝑒𝑒𝑡ℎ
5
Summary Of Gear Torque:
GEAR TEETH TORQUE (Nm)
X 16 3.815
A 105 25.04
D 32 7.63
C 32 7.63
B 65 15.5
All these are calculated using the standard torque ratio formula mentioned in Shigley’s design:
𝑇1 𝑁2
=
𝑇2 𝑁1
Forces On Gears:
Using:
𝑑𝑝
Torque = 𝐹𝑡 ×
2
𝑇
𝐹 = 2𝑥
𝑑𝑝
Pitch Diameters:
- Gear X: 30.54 mm
- Gear A: 200.5 mm
- Gear B: 124.05 mm
- Gear C/D: 61.08 mm
Force Calculations:
Gear X:
3.81
𝐹𝑡 = 2 × = 249.80 N
0.0305
Gear A:
25.04
𝐹𝑡 = 2 × = 249.80 N
0.2004
Gear C/D:
7.63
𝐹𝑡 = 2 × = 249.80 N
0.0611
6
Gear B:
15.50
𝐹𝑡 = 2 × = 249.80 N
0.1241
Lewis Bending Stress:
𝐹𝑡
σ =
(b × m × Y)
• σ = Bending stress (MPa)
• Ft = Tangential load on gear tooth (N)
• b = Face width (mm)
• m = Module (mm)
• Y = Lewis form factor (dimensionless)
Gear X: Y = 0.245
249.80
σ = = 53.41 MPa
(10 × 1.909 × 0.245)
Gear A: Y = 0.39
249.80
σ = = 33.55 MPa
(10 × 1.909 × 0.39)
Gear C/D: Y = 0.322
249.80
σ = = 40.64 MPa
(10 × 1.909 × 0.322)
Gear B: Y = 0.38
249.80
σ = = 34.44 Mpa
(10 × 1.909 × 0.38)
AGMA Bending Stress:
K o = 1.25 (shock), K v = 1.3 (medium precision), K s = 1.0, J ≈ Y
𝐹𝑡 × 𝐾𝑜 × 𝐾𝑣 × 𝐾𝑆
σ𝐴𝐺𝑀𝐴 =
(b × m × J)
GEAR X:
249.80 × 1.25 × 1.3
σ𝐴𝐺𝑀𝐴 = = 86.79 MPa
(10 × 1.909 × 0.245)
GEAR A:
249.80 × 1.25 × 1.3
σ𝐴𝐺𝑀𝐴 = = 54.52 MPa
(10 × 1.909 × 0.39)
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GEAR D/C:
249.80 × 1.25 × 1.3
σ𝐴𝐺𝑀𝐴 = = 66.04 MPa
(10 × 1.909 × 0.322)
GEAR B:
249.80 × 1.25 × 1.3
σ𝐴𝐺𝑀𝐴 = = 55.96 MPa
(10 × 1.909 × 0.38)
AGMA Strength Check:
Allowable Bending Stress (Mild Steel) = 100 MPa
Gear X: σ𝐴𝐺𝑀𝐴 = 86.79 MPa → SAFE
Gear A: σ𝐴𝐺𝑀𝐴 = 54.52 MPa → SAFE
Gear D: σ𝐴𝐺𝑀𝐴 = 66.04 MPa → SAFE
Gear C: σ𝐴𝐺𝑀𝐴 = 66.04 MPa → SAFE
Gear B: σ𝐴𝐺𝑀𝐴 = 55.96 MPa → SAFE
All values are below allowable 100 MPa. Safe.
8
CHAPTER 03 CAD MODULING AND SIMULATION
3.1 INTRODUCTION
To validate the mechanical performance and strength of the designed gear under operating
conditions, a 3D CAD model of the gear was created using standard modeling software. The model
was then imported into ANSYS for structural simulation. This analysis helps visualize the stress
distribution, deformation, and safety of the gear design under calculated loads.
3.2 Finite Element Analysis In ANSYS
3.2.1 SIMULATION SETUP
The 3D model was imported into ANSYS Workbench. The following setup was applied:
• Analysis Type: Static Structural
• Material Assigned: Mild Steel (AISI 1020)
o Young’s Modulus: 2.1 × 10⁵ MPa
o Poisson’s Ratio: 0.3
o Yield Strength: 350 MPa
• Mesh: Fine mesh with refinement at gear teeth (especially at root fillets)
• Boundary Conditions:
o One side (hub or center hole) fixed
o Tangential force (calculated from torque) applied on gear teeth as surface pressure
The simulation report is attached at the end of this report.
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3.3 CAD MODEL:
Figure 1 ISOMETRIC DRAWING
Figure 2 FRONT VIEW
10
Figure 3 SIDE VIEW
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CHAPTER 04 GEAR BOX SELECTION
4.1 INTRODUCTION
This chapter outlines the selection and justification of a commercially available gearbox
(NRV040) for the capsule-making machine. It also presents a technical comparison between the
custom-designed multi-stage spur gear train and the selected worm gearbox. The goal is to validate
the suitability of a real-world solution while understanding the trade-offs in performance,
efficiency, and integration.
4.2 COMMERCIAL GEARBOX SELECTION:
Catalog name: TECHNICAL CATALOGUE_VSF_IEC_STD_EN_rev0_2017.pdf
Model: NRV040
Selection Details:
- Reduction Ratio (i): 5.00
- Rated Torque (Mn₂): 24 Nm
- Rated Input Power (Pn₁): 1.56 kW
- Output Speed (n₂): 560 RPM
- Radial Load (Fr₂): 912 N
- Radial Load (Fr₂): 912 N
4.3 SELECTION JUSTIFICATION
Criteria Requirement NRV040 Verdict
(Selected)
Torque 15.5 Nm 24 Nm Safe
Input Power 1.12 kW 1.56 kW Safe
Output Speed 689.65 RPM 560 RPM Acceptable
Radial Load Moderate 912 N Safe
Support
12
Safety Margin for Torque: 24 / 15.5 = 1.55 (or 55% margin)
4.4 CONCLUSION:
The NRV040 gearbox with i = 5.00 and Mn₂ = 24 Nm is a suitable and safe choice for the capsule-
making machine, fulfilling all mechanical and operational requirements with appropriate margins.
13
CHAPTER 05 DISCUSSION:
5.1 DISCUSSIONS
The gearbox design and commercial selection processes were both approached with technical
rigor and real world constraints in mind. A comparative analysis reveals the following key
insights:
CUSTOM GEARBOX DESIGN VS. COMMERCIAL GEARBOX (NRV040):
Commercial Gearbox
Aspect Custom Gearbox Design
(NRV040)
Gear Type Multi-stage Spur Gear Train Worm Gear
Calculated Torque Output 15.5 Nm (at Gear B) Rated 24 Nm
Output Speed 689.65 RPM 560 RPM
Power Handling 1.12 kW (motor) Rated 1.56 kW
All gears passed AGMA Pre-rated by manufacturer; no
Stress Analysis bending stress checks (Max = further stress validation
86.79 MPa < 100 MPa) needed
Lower due to worm gear
Efficiency Higher due to spur gear usage
sliding action
Fully customizable for exact Limited to standard catalog
Design Control
application needs specifications
Compact, enclosed system
Modular, familiar gear
Ease of Maintenance with fewer maintenance
configuration
needs
Designed near requirement 55% higher than required
Safety Margin (Torque)
limits torque (safe buffer)
14
5.2 PERFORMANCE & SUITABILITY COMPARISON:
• The custom-designed gearbox offers a detailed understanding of internal gear mechanics
and is optimized specifically for the capsule-making application using spur gears. Its main
advantage lies in high efficiency and mechanical simplicity, suitable for moderate-speed,
precise timing operations.
• The commercial gearbox (NRV040) provides a compact, pre-engineered solution with
significant safety margins in torque and power. Although worm gears typically have lower
efficiency, the selected model compensates with its robustness, ease of integration, and
minimal alignment requirements.
5.3 VALUE OF BOTH APPROACHES:
The custom design process helped deepen understanding of gear calculations, torque distribution,
and stress analysis, offering flexibility in modifying individual gear stages. On the other hand, the
commercial selection ensures practical feasibility, reduced lead time, and tested reliability from a
certified manufacturer important factors for real-world industrial deployment.
15
CHAPTER 06 CONCLUSION
6.1 SUMMARY:
This report addressed a complex engineering problem by designing a custom gear train for a
capsule-making machine and evaluating a commercially available gearbox that meets the same
operational requirements. The design process involved selecting spur gears, performing detailed
torque and stress calculations, and validating the results using AGMA standards. All designed
gears were found to operate safely within the material limits, demonstrating the feasibility and
reliability of the proposed gear system. The commercial gearbox (NRV040) selected from the
manufacturer’s catalog was analyzed and found to be suitable, offering a torque output 55% higher
than required, with adequate power handling and acceptable speed reduction. Although it uses a
worm gear configuration less efficient than spur gears it provides advantages in compactness,
durability, and ease of integration. The comparison highlights the importance of understanding
both theoretical design and practical selection. While custom gear design allows for precision and
adaptability, commercial solutions offer simplicity and industry-tested reliability. Ultimately, both
approaches are critical in industrial design scenarios where performance, safety, and feasibility
must be balanced.
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