GEARBOX DESIGN FAQs

ASSIGNMENT

ABOUT THIS DOCUMENT

The purpose of this document is to share the commonly asked questions.
It does not add, delete or modify any of the specifications / requirements. The assignment specifications and requirements remain the same, as outlined in the original assignment description document.

MODULE SELECTION
What module do I use to transfer the required amount of torque?
Selecting an exact module requires analysing several factors, such as gear material, torque/power, gear-tooth bending & wear, surface durability. Such analysis is beyond the scope of this assignment. Any module based on your best judgment will be acceptable.

To get some idea of the required module, inspect the torque carrying capacity of gears. Some manufacturers (e.g. khk) do provide the torque carrying capacity of their gears.

GEAR SIZE
What if my worked-out gears are not available in the gear catalogues?
Take the required information from the closest available size.

BENDING MOMENT
What value of the Bending Moment do I use in the formula for shaft diameter?
Determine the resultant value by considering the bending moment diagrams for vertical and horizontal forces.

(Refer to the power point presentation on procedure for design of a shaft)

STRESS CONCENTRATIONS
How do I decide the stress concentration factors?
It depends on the shaft geometry and loading:

In case of uniform torque, stress concentration is neglected when considering the torsional shear However, the bending moment is fully reversed. Therefore, the stress concentration should be considered. Initially, these values are selected based on engineering judgment. Consider factors like shaft shoulders, retaining ring grooves etc. Verify your assumptions once the shaft dimensions are known.

For this assignment, the stress concentration factors can be ignored. However, stress relieving strategies need to be discussed in the relevant sections of your report.

FATIGUE LIFE FACTORS

How do I decide the fatigue life factors?
These factors depend on the properties (e.g. surface finish, reliability etc) of your selected shaft and shaft material. Proper selection of these factors requires knowledge of fatigue failure, which is discussed in Materials 337 unit.

Your best judgment will be acceptable.

SHAFT DIAMETER
What if the calculated shaft diameter is larger than the bore size of my selected gears? Try stronger material for the shaft.

SHAFT DIAMETER & BEARING BORE SIZE

What if the bearing bore size is larger than the shaft diameter?
There are several ways to overcome this problem. Radial contact ball bearings Angular contact ball bearings Radial contact roller bearings Angular contact roller bearings Needle roller bearings Multi-row ball bearings
Within each of these categories, try X-light, light, and medium duty bearings.