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Project One

The project aims to design a two-stage compound reverted gearbox speed reducer to efficiently transmit mechanical power while significantly reducing rotational speed. Key design elements include an intermediate shaft, stress analysis, bearing selection, and ensuring the gearbox fits within specified dimensional constraints. Next steps involve gear design, shaft design, bearing selection, and housing design.

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25 views3 pages

Project One

The project aims to design a two-stage compound reverted gearbox speed reducer to efficiently transmit mechanical power while significantly reducing rotational speed. Key design elements include an intermediate shaft, stress analysis, bearing selection, and ensuring the gearbox fits within specified dimensional constraints. Next steps involve gear design, shaft design, bearing selection, and housing design.

Uploaded by

shaleshjon605
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

Mechanical Engineering Design Project O ne : Two-Stage Compound Reverted Gearbox

Reducer

Project Objective

Design a gearbox speed reducer to transmit mechanical power efficiently while achieving a
substantial reduction in rotational speed. The design focuses on the intermediate shaft and
its associated components, within the constraints of a compact, in-line gearbox layout.

System Configuration

The gearbox employs a two-stage, compound reverted gear train as illustrated:

• Gear 2 and Gear 3 are mounted on the input shaft

• Gear 4 and Gear 5 are mounted on the output shaft

• The intermediate shaft carries two gears: Gear 3 and Gear 4, providing compound
gear functionality

The reverted configuration ensures that the input and output shafts are in-line, a crucial
requirement for the compact gearbox housing.
Design Inputs and Constraints

Parameter Value

Input Power 20 hp

Input Speed 1750 rpm

Output Speed 82–88 rpm

Gearbox Base Size 35.56 cm × 35.56 cm

Gearbox Height (Y) ≤ 55.88 cm

Shaft Extensions 10.16 cm from gearbox

Load Condition Low shock loading

Shaft Alignment Input and output shafts in-line

Design Focus: Intermediate Shaft

The intermediate shaft connects:

• Gear 3 (meshing with Gear 2): Receives power from input shaft

• Gear 4 (meshing with Gear 5): Transfers power to the output shaft

The design of this shaft includes:

• Stress analysis: Torsional and bending loads due to gear reactions

• Deflection control: To maintain gear alignment

• Bearing placement: For proper support and load distribution

• Keyways or splines: For gear mounting

• Material selection: High-strength alloy steel

• Vibration analysis

Bearing Selection

Requirements:

• Life > 12,000 hours

• Operating Hours:

o 8 hours/day

o 5 days/week
o 52 weeks/year
→ 2,080 hours/year
→ Target lifespan: ≥ 5.77 years

Design Criteria for Ball Bearings:

• Select deep groove or angular contact ball bearings based on radial and thrust load
combinations.

Conclusion and Next Steps

This project requires:

1. Gear design and selection: Based on velocity ratio and gear strength

2. Shaft design: Based on bending, torsion, and combined loading

3. Bearing selection: Meeting life and load requirements

4. Gearbox housing design: Ensuring fit within dimensional constraints

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