ASSIGNMENT

GEARBOX DESIGN

ABOUT THIS DOCUMENT

This document 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.

GEARBOX DESIGN
Power to be delivered
Steady-state input speed
Steady-state output speed

Output shaft and input shaft in-line (Not essential)

Base mounted with 4 bolts
Mounting orientation only with base on bottom

1 kW
150 rpm
2000 + 2 rpm

GEARBOX DESIGN

The gearbox is targeted for uniformly loaded

applications, such as conveyors, belts, blowers,
and generators.

The expected life of the unit is 6 years, which

is based on 8 hours per day and 5 days a week.

A maximum of 3% failures are allowed over the

design life of the unit.

SUGGESTED STRATEGY
Prepare an outline design of what you want to
achieve and consider all the possible ways it can
be done.
The simplest solution is usually the best.
How will you achieve the required output, and
how will you package the gears?
What mountings do you require on the
gear/bearings and what shaft arrangements?

ASSUMPTIONS?
Carefully read the given data, and if
required, make the necessary assumptions.
Check if you need to comply with any
standard values while assuming certain
parameters.
For example: Pressure angle, module ?

POWER REQUIREMENT
Address the power considerations, as this will help
you determine the overall sizing needs for the entire
system.
Any necessary speed or torque ratio from input to
output must be determined before addressing gear
sizing.
Any power losses?

Gear efficiency, friction in bearings ???

You may like to consider 100% gear efficiency and no friction in the rolling
element bearings. Such considerations should be part of your assumptions.

GEAR SIZES
Select gears of appropriate sizes to achieve the
identified ratios. (Follow the procedure, which is explained in the
lecture notes and tutorial problems).

Care should be taken at this point to select the best

combination of teeth numbers to minimise the
overall package size (i.e. gearbox size).
A difference of one tooth on the smallest gear can
make a significant impact on size of the overall
package.

GEAR SPECIFICATIONS
Gear specs such as gear outside diameters, hub
dimensions, face widths, mounting distance etc., would
help you to determine the gearbox size and shaft
length.
Miniature Bearings Australia
KHK Stock gears

(http://www.minibearings.com.au)
(http://www.khkgears.co.jp/en/)

Tea Transmissions Pty Ltd

(http://www.tea.net.au)

SHAFT LAYOUT
Decide the shaft layout the axial location of gears
and bearings must now be determined.

It is extremely important to keep axial distances small.

A small increase in axial distance will result in large increase in

bending moments.

Your best judgment for clearances between different components of

the gearbox will be acceptable.

All working must be shown.

Prepare a rough sketch to visualize your proposed

design.

FORCE ANALYSIS
Once the gear diameters are known, and the axial
locations of the gears and bearings are known:
Construct free-body diagram
Determine the forces at the bearings.
To determine the loads applied to bearings, you can follow the procedure explained in Problem 7
(Tutorial 4). Remember, that particular procedure is for spur gears. In case of helical gears, the axial
force should also be considered .

Now, shear-force and bending moment diagrams for

the shafts can be constructed.

SHAFT MATERIAL
Conduct a review of the literature on shaft
materials,
Select an appropriate material,

A reasonable value of factor of safety should

be considered. State it clearly.

SHAFT DIAMETER

Based on your shear-force and bending moment

diagrams, determine the estimates for shaft
diameter.
Identify the stress raisers. These are the
regions where the stress concentrations will
be very high. For example, shaft shoulders,
key-seats, grooves for retaining-rings etc.

Investigate strategies to reduce stress

concentrations in the shafts and shaft components.

STRESS CONCENTRATION FACTORS

Select and use the values of stress
concentration factors appropriate to
the shaft location under consideration
These values are based on the your
selected mechanisms for transferring
torque and securing the axial location
of components.

SELECT BEARINGS

Select suitable bearings.

Consider radial as well as axial loads.

Bearing dimensions can be obtained from

online catalogues, lecture notes / Juvinall
textbook.

NOTE:
You may need to modify the shaft diameter to facilitate
the assembly of bearings and gears.

SELECT PLAIN BEARINGS

Low friction materials are available in many
forms.
Investigate and put forward your choice.
Discuss its lubrication requirements (if any).

The reasons why you wish to use it.

NOTE:
Do not do calculations on plain bearing forces/pressures simply show
the shapes, sizes and positions of those bearings in your design.

TORQUE TRANSFER
Make decisions on how to transfer torque from shafts
to gears.

For example, keys, splines etc.

Perform stress analysis

How are you going to hold gears and bearings in

place?

For example, shaft shoulders, pins, retaining rings etc.

(You are not required to perform strength analysis of these elements

type, shape description and their location in the proposed design would be
enough).

FINAL ANALYSIS
Prepare a detailed sketch illustrating the exact
location of each component, and their relationship
with each other.
Perform a formal analysis.
If required, make the necessary modifications.
Determine the type of fits (stick to ISO preferred
fits). Calculate the shaft dimensions (tolerances).

GEARBOX CASING
Decide casing arrangements. Consider the
followings to determine the overall casing
dimensions:

Size of gears and bearings

Length of shafts
Clearances
Strength/stress analysis of the casing is not required. Your best judgment for the
casing material and wall-thickness will be acceptable.

REPORT WRITING
Check the page limits and
formatting requirements on the
last page of the assignment brief.
Preparing your report as per the
stated
requirements
is
an
essential requirement.

Good Luck!
Please feel free to contact me if you have any
questions.