Jimma University

Institute of Technology
faculty of Mechanical Engineering

DESIGN PROJECT PHASE TWO

GROUP FOUR SUB-GROUP 8

DESING OF GEAR BOX (PERPENDICULAR ALIGNMENT)

NAME ID NO

1. Naol Daselegn …………………………………………………………RU3533/09

2. Abraham Mihiretu……………………………………………………RU4362/09

3. Beka Tamene…………………………………………………………..RU2091/09

4. Mamush Taddese…………………………………………………….RU1546/09

5. Mahalet Getachew…………………………………………………..RU

6. Hana Mamo…………………………………………………………….RU0870/07
 ACKNOWLEOGMENT
First of all we would like to thanks ‘God’ due to Almighty God alone us who give power and
sustain us from start to ends throughout our project.

Next, we would also thanks our instructor MSc Abiyou Solomon for his commitment to teaching
and guiding process for that he made great effort for us to take knowledge through this design
project and becomes mature for any design in future.

Lastly, we have thanks for any members who had supported us and our group students in
writing, searching, analyzing and organizing different data from internet, books and other
services to finish this project in time.
ABSTRACT
This project focuses on complete analysis and design of ‘Gear box’ for this design geometric
analysis, force analysis, strength analysis and shear force calculated. For this design some
standard machine elements components are selected for design of gear box. For improvement
of power transmit rate and design of suitable gear box appropriate material are selected.
Finally after all dimensions are completed and materials are described for design components,
the assembly drawing for complete description of suitable gear box is drawn.
1 Contents
ABSTRACT ..................................................................................................................................................................3

CHAPTER ONE ........................................................................................................................................................ 6

1.1INTRODUCTION................................................................................................................................................. 6

1.2 SCOPE OF STUDY .............................................................................................................................................. 6

1.3 OBJECTIVES OF PROJECT .................................................................................................................................. 7

1.3.1 GENERAL OBJECTIVES .............................................................................................................................................7

1.3.2 SPECIFIC OBJECTIVES ..............................................................................................................................................7

1.4 MAIN COMPONENTS OF GEAR BOX ................................................................................................................. 7

1.5 GEAR DESIGN CONSIDERATION ........................................................................................................................ 8

1.6 SOME POSSIBLE GEAR REDUCTION ASSEMBLY MECHANISM ........................................................................... 9

1.7 SOME GENERAL ASSUMPTION OF GEAR BOX DESIGN ...................................................................................... 9

1.8 MATERIAL SELECTION .................................................................................................................................... 10

1.9 DESIGN SPECIFICATION .................................................................................................................................. 11

1.10 GEAR SPECIFICATION ................................................................................................................................... 12

CHAPTER TWO ..................................................................................................................................................... 13

2.1 GEAR BOX DESIGN (PERPENDICULAR ALIGNMENT) ........................................................................................ 13

2.2GEAR MATERIALS ............................................................................................................................................ 16

2.3 STAGE ONE..................................................................................................................................................... 17

2.3.1DIAMETER OF PINION AND GEAR ....................................................................................................................17

2.3.2FORCE ANALYSIS OF PINION AND GEAR ..........................................................................................................18

2.4GEOMETRY/DIMENSIONS OF GEARS OF BEVEL GEAR ..................................................................................... 19

2.5AGMA STRESS EQUATIONS ............................................................................................................................. 21

2.6FORCE ANALYSIS OF PINION AND GEAR .......................................................................................................... 29

2.7SHAFT DESIGN................................................................................................................................................. 32

2.7.1SHAFT CALCULATIONS .....................................................................................................................................33

2.7.2INPUT SHAFT ...................................................................................................................................................33
2.7.3OUTPUT SHAFT ....................................................................................................................................................37

2.8BEARING SELECTION ....................................................................................................................................... 42

2.8.1 BEARING SELECTION FOR INPUT SHAFT .....................................................................................................................42

2.8.2BEARING SELECTION FOR OUTPUT SHAFT .......................................................................................................43

2.9 DESIGN OF KEY ............................................................................................................................................... 44

2.9.1 DESIGN OF KEY – 1 ..........................................................................................................................................45

2.9.2 DESIGN OF KEY -2 ................................................................................................................................................46
2.10 DESIGN OF GEAR HOUSING BOX .................................................................................................................. 47

CHAPTER THREE ................................................................................................................................................... 49

3.1LUBRICATION .................................................................................................................................................. 49

3.2SELECTION OF LUBRICATION FOR GEAR .......................................................................................................... 49

3.3 LUBRICATION FOR BEARING .......................................................................................................................... 49

3.4 PROPERTIES OF LUBRICATION ........................................................................................................................ 49

REFERENCE .......................................................................................................................................................... 52
CHAPTER ONE

1.1INTRODUCTION
A gear box, also known as a gear case or gear head is a gear or a hydraulic system responsible
for transmitting mechanical power from a prime motor (an engine or any electrical motor) in to
some form of useful output. It is referred to the metal casing in which a number of gears are
sealed. A gear box is also a set of gears for transmitting power from once rotating shaft to
another.

Gear boxes are used in almost expert industry right from machine, agriculture, textile,
automobiles, aerospace, shipping turbine drive etc. these are the different types of gear box
available for different uses. They are constructed from different from different materials
depending on their end use and the kind of industry they are used in. the product has
numerous industrial applications for providing high torque and smooth speed reduction with a
very low loss power.

Gear boxes are manufactured by keeping certain specification in mind, which will also very
depending on the application and some standard assumption to be used. The design of gear
box can be depend on some parameters like, bending strength, pitting, cutting (high speed
gear) considerations. Speed reducer gear can be used in all industry that they reduce speed and
increase torque. An industrial box is a machine used for the majority of drives requiring a
valuable lift and factor of safety and with the pitch once velocity of the gears limited to below
𝑚
25 𝑠

1.2 Scope of study

 Design of gear box that are efficient and improved rating power with power input of 6
kilowatt (6KW), input speed of 1400 revolution per minute (1400RPM), gear ratio of 10
and alignment of shaft input and output are perpendicular. However, there is for
readme purpose similar project for general specification with a selection of better
engineering materials are occurred.
 1.3 Objectives of project
1.3.1 General objectives
 To apply the knowledge obtained from studying in the university and solve the suitable
task of creating a design of the appropriate machines and its components.

1.3.2 Specific objectives

 To design a gear box which is safe efficient and improved rating power
 To choose the material for derived design of gear box
 To fabricate proto type of gear box with its specification.

To calculate and analysis the inner stress for parts and 2-Dimansional model of gear box.

1.4 Main Components of Gear Box

 Frame - is used support bearing horse or it is generally the supporter of all parts of
gear box for proper performance.

- It is also used for gear, lubricant and other parts of gear box to be protected
from external damages such as dusts and corrosion from external environments.
 Gear - is a rotary machine parts having cut teeth which much with another toothed part
in order to transmit torque.

- It is used for increasing speed, increasing force or change direction of the power
source.
 Shaft - is a machine element which is circular in cross –section and used to transmit
power and torque by using power transmission elements such as gear, pulley,
sprocket…etc.
 Bearing – is a machine element that contract relative motion and reduce rotational
frictional between moving parts to only the desired once and supports radial and thrust
loads.
 - Bearing is also a rotating support placed between components to support or
increase movement and reduce friction.

- Reducing friction in bearing is important for efficiency, to reduce wear and to

facilitate extended use at high speeds and to avoid heating and pressure failure
of bearing.
 Key - is a machine element to connect a rotating machine element to s shaft.

It can be used as temporary faster, and are subjected to shearing and crushing or
compression stress.

1.5 Gear Design Consideration

The load speed and rating of the special operation condition must be defined as a first
step in designing a gear set for a specific application. A basic load and a suitable factor
in compassing protection from specific life safety are determined from;

A, The power rating of the prime mover, its over load potential and the uniform of its
and put to fuel.

B, the normal output loading, peak loading and flair duration the possibility of stalling
or lever loading at in prefect interval

C, inertia loads, arriving from acceleration or declaration

The speed at which a gear set will operate must be known to determine inertia loads,
velocity factor type of gear required accuracy requirement design of moving and the
type of lubrication

The main gear design consideration in design of gear box include the following

 Application requirements
 Selection of the type of gear
 Estimated gear size
  Number of teeth required
 Face width of gear
 Diametric pitch of the gear

1.6 Some Possible Gear Reduction Assembly Mechanism

A gear a train valve of up to 10 to 1 each can be obtained with one pair of gear. Greater ratio
can be obtained in lets space and with fewer dynamical problems by compound gear train can
obtain their valve of up to 100 to 1.

𝐩𝐫𝐨𝐝𝐮𝐜𝐭 𝐨𝐟 𝐝𝐫𝐢𝐯𝐢𝐧𝐠 𝐭𝐨𝐨𝐭𝐡 𝐧𝐮𝐦𝐛𝐞𝐫

𝐓𝐫𝐚𝐢𝐧 𝐯𝐚𝐥𝐯𝐞 = 𝐩𝐫𝐨𝐝𝐮𝐜𝐭 𝐨𝐟 𝐝𝐫𝐢𝐯𝐞𝐧 𝐭𝐨𝐨𝐭𝐡 𝐧𝐮𝐦𝐛𝐞𝐫

Thus, in this gear box design we have a total gearing ratio of 16 which is in the range train valve
100 to 1, i.e. Gear ratio greater than 10.

There for, we used two stage of reduction in speed.

Two stage gear reduction with co-axial input shafts and output shafts is more suitable gear
assembly for the design of gear box because it is important to:

 decrease the length of gear box

 decrease the number of bearing up needed in gear box design
 more coupactest and small size of package
 decrease the length of shaft that used to decrease the deflection of
shaft.

1.7 Some General Assumption of Gear Box Design

 For any gear having pitch circle diameter greater than 100nm. Would be product
with hurls, rims and way in order to reduce its weight, especially for bevel gears
 tooth profile are standard involute
 gears used in gear box design must along their pitch circles and the point is so called
pitch point
 All loads are transmitted at the pitch points and mid planes of the gears
 All power losses are assumed to be negligible,
 I.e. power input = power output
 The pressure angle 200 full depth in volute, so that is the equal addendum and full
depth teeth that increases the contact ratio, avoids under cut and increase the
strength of pinion
 Gears are mounted of the middle of the shaft
 Weight of gears are negligible
 Design of gear and bearing are according to American Gear manufacturing
Association (AGMA) standard.
 Due to gear ratio, less than 10:1 we prefer to use one steps of reduction of speed.

Steel:- is used for high strength gears and it may be plain carbon steel or alloy steel. The steel
gears are usually heat treated in order to combine properly the toughness and teeth hardener

More over steel

 Has higher strength, hardness and toughness

 High values of hardness and strength can be achieved for components
with large section thickness
 Passes higher hardenability
 Retains its strength and hardness at elevated temperature

A good combination is often steel pinion moshed against cast iron gear. Steel finds manly
application since is combines both high strength and low cost.

This is because it has a very low cost, is easy cost in large quantities and easy to machine.

1.8 Material selection

A range of gear boxes are constructed from a variety of materials depending on the industry or
the product in which they are being used for. Fine quality materials are used to maintenance
gear boxes for ensuring reliability case of maintenance and long life.

The main factors which should be considered while selecting the material for a machine
component are:-
  Availability
 Cost
 Mechanical properties
 Manufacturing

Depending up on the above criteria cast iron is used for gears due to:-

 Its good wearing properties

 Excellent machinability
 Raise of producing complicated shapes without involving costly
machining operation casting method
 The tool used for casting is simple and in expensive
 A valuable in a large quantities
 Has higher compression strength
 Has an excellent ability to
 Has more resistance to wear even under the condition of
boundary lubrication.

Bc ROUGH ASSEMBLY OF GEAR AND SHAFT

Ba

G2

S2

Output shaft
 1.9 Design specification
 A subset of design specification that will be needed for this (gear box) part of deign are
given hear.

Power to delivered, p = 6000 = 6KW

Input speed, n1 = 1400RP

Arrangement of shaft for input and output shaft are perpendicular

Gear ratio, G = 10

1.10 Gear specification

Gear specification is depending on the given information about the gear. It depends on the
arrangement of the input and output shaft, that train valve and the power given by the motor
to enable for the required operation of the drive machine.

It includes separating the particular gear types (selecting gear type) with their particular
advantages over the other.

It also includes specifying the reduction stages for the gearing ratio. Depending on the above
introduction gear specification messages we are going to specification gears

 Depending on the given data. We select a one stage speed reduction. The reason why
preferring it is that for a given gear ratio say G as 1≤G≤10 and since the power is not
as so large it can be one stage of speed reduction.

NOTE: - the arrangement of shaft is given the perpendicular. So that bevel gear is the best
drive to transmit power to perpendicular shaft.
The once stage speed reduction are arranged in a proper way to transmit as much the given
power smoothly.

 Gears used as one stage speed reduction are straight teeth bevel gears.

The reason to use it over spiral bevel gear is the straight teeth bevel gears are
 Easy to manufacture.
 Not costly due to its simplicity of manufacture.
 It only reduces the sped as required.

CHAPTER TWO

2.1 GEAR BOX DESIGN (perpendicular alignment)

Gear box is one of the essential mechanical device that is a collection of gears, shafts, bearings
and other mechanical parts and it is used for the reduction or multiplication of speed and torque.
Gear box is used to multiply engine (motor) torque or reduce engine (motor) speed (rpm) to
much varying forward operating conditions. To achieve these results the transmission (gear box)
employs different gear ratios.We will use spur gears since it’s advantageous due to its quite
operation, smooth drive and high efficiency off transmission.

CONSTRUCTION OF GEAR BOX

Gear box is constructed from the following major components;-
 Pinion Gears and larger gears
 Shafts
 keys
 Bearing selection
 Gear box housing

Specification
 Power = 6 KW
 Input Speed = 1400 rpm
  The crane speed from the first feeder table to the next feeder table is well
assumed according to the crushing rate of the factory and we select the
output speed and then further reduction of the speed is done by chain.
 Type of gears = Bevel gear
 Pressure angle =20
 Gear box type -single stage reduction gear box.
 Used to reduce the speed and increase the torque from prime mover to the
machine.
𝒊𝒏𝒑𝒖𝒕 𝒔𝒑𝒆𝒆𝒅
𝑮𝒆𝒂𝒓 𝒓𝒂𝒕𝒊𝒐 =
𝒐𝒖𝒕𝒑𝒖𝒕 𝒔𝒑𝒆𝒆𝒅

For gear ratio between 1 < 𝐺𝑟 ≤ 10 it is recommended to use one or two stage gear box type.
So in our case we select one stage reduction gear box.

First stage

Determination of speed for each gear

Let us represent the speed of gears by capital letter N

N1- input gear speed (gear1)

N2-output gear speed (gear2)

Gear ratio =10

1 𝑁1
Train value𝑒 = 10 = 𝑁2

𝑁1 1400
𝑁2 = =
𝐺 10

𝑁2 = 140𝑟𝑝𝑚 − 𝑜𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑

Torque of the Shaft/Gear

Let us represent T1= torque on shaft one (gear1)

T2= torque on shaft two (gear2)

 𝑝𝑜𝑤𝑒𝑟 = 𝑇 × 𝑤 𝑤ℎ𝑒𝑟𝑒 𝑇 − 𝑡𝑜𝑟𝑞𝑢𝑒 𝑎𝑛𝑑 𝑤 − 𝑎𝑛𝑔𝑢𝑙𝑎𝑟 𝑠𝑝𝑒𝑒𝑑

2𝜋𝑁
𝑤=
60

𝑃𝑖𝑛𝑝𝑢𝑡 = 𝑝𝑜𝑢𝑡𝑝𝑢𝑡

𝑝1 = 𝑇1 × 𝑤1

𝑃
𝑇1 =
𝑤1

6000
𝑇1 = 60 ×
2𝜋1400

𝑇1 = 40.946𝑁𝑚

Since 𝑝𝑖𝑛𝑝𝑢𝑡 = 𝑝𝑖𝑛𝑝𝑢𝑡

𝑃1 = 𝑃2

Determination of Gear diameter for analysis

To determine the gear diameter of we strongly depend on module assumption

The assumption of module depend on consumption of

- gear ratio - tooth thickness

- gear size of a box - number of stage of reduction

For bevel gear we have the following the same procedures because their number are not much
different so assume module m=6

𝐷 𝐷1 𝐷2
𝑚= = =
𝑁 𝑁1 𝑁2

𝐷1
6=
8
 𝐷1 = 48𝑚𝑚(𝑝𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑓𝑜𝑟 𝑝𝑖𝑛𝑖𝑜𝑛)

𝐷2 = 𝑁2 × 6 = 80 × 6 = 480𝑚𝑚(𝑝𝑖𝑡𝑐ℎ 𝑐𝑖𝑟𝑐𝑙𝑒 𝑑𝑖𝑎 𝑓𝑜𝑟 𝑔𝑒𝑎𝑟)

For bevel gear, face width is approximately as

𝐵 = 10𝑚 = 10 × 6 = 60

𝐷𝑝 48
Pitch cone angle on Bevel Gear says 𝜃𝑝 = tan−1 𝐷𝑔 = tan−1 480 = 5.7

480
𝜃𝑔 = tan−1 = 84.3
48

2.2GEAR MATERIALS
The material used for the manufacture of gears depends upon the strength and service conditions
like wear, noise etc. The gears may be manufactured from metallic or non-metallic materials.
The metallic gears with cut teeth are commercially obtainable in cast iron, steel and bronze. The
steel is used for high strength gears and steel may be plain carbon steel or alloy steel. The steel
gears are usually heat treated in order to combine properly the toughness and tooth Hardness due
to this property we select heat treated alloy steel for gear material.

For the designing of bevel gear 18CrNiMo case-carburized steel is selected because of better
mechanical property.

GEAR MATERIAL SPECIFICATION

Material specification Value

Surface hardness HRC 61

Tensile strength 1200Mpa

Yield strength 850Mpa

Poisson’s ratio 0.3

Young’s modules 206000MPa

 Table 1 gear material properties

2.3 STAGE ONE

The smallest number of teeth on the pinion without interference is given by:

2𝑘
𝑇𝑝 = (𝑚 + √𝑚2 + (1 + 2𝑚)𝑠𝑖𝑛2 ɸ)
(1 + 2𝑚)𝑠𝑖𝑛2 ɸ

Where

 𝑇𝑃 = number of teeth on the pinion

 𝐾 =1
 𝑚 = 𝑀𝑂𝐷𝑈𝐿𝐸 = 6
 ɸ = 𝑝𝑟𝑒𝑠𝑢𝑟𝑒 𝑎𝑛𝑔𝑙𝑒 = 20𝑜

𝑇𝑃 = 8 𝑡𝑒𝑒𝑡ℎ

Now let find the gear teeth (𝑇𝐺 )

𝑇𝐺
𝐺𝑟 = , 𝑇𝐺 = 𝐺𝑟 𝑥 𝑇𝑃 = 80𝑥6 = 480𝑡𝑒𝑒𝑡ℎ
𝑇𝑃

From the standards given we select module 6mm

𝑝𝑖𝑡𝑐ℎ 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟
𝑚=
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ

2.3.1DIAMETER OF PINION AND GEAR

Diameter of pinion
𝐷𝑃 = module x Number of teeth of pinion = m x 𝑇𝑃 = 6mm x 8mm
𝐷𝑃 = 48mm
Diameter of gear
𝐷𝐺 = module x Number of teeth of gear = m x 𝑇𝐺 = 6mm x 80mm
𝐷𝐺 = 480mm
 2.3.2FORCE ANALYSIS OF PINION AND GEAR
This tangential load is really the useful component, because the radial component serves no
useful purpose. It does not transmit power.

60 000H
Wt =
Πdn

Where 𝑊𝑡 = 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑙𝑜𝑎𝑑, 𝑘𝑁

𝐻 = 𝑝𝑜𝑤𝑒𝑟, 𝑘𝑊
𝑑 = 𝑔𝑒𝑎𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚𝑚
𝑛 = 𝑠𝑝𝑒𝑒𝑑, 𝑟𝑒𝑣/𝑚𝑖𝑛

60 000 ∗ 6KW
Wt = = 170.54N
Π ∗ 90mm ∗ 1400rpm

Know we can resolve tangential load into axial and radial component

𝑊𝑎12 = 𝑊𝑡𝑡𝑎𝑛∅𝑠𝑖𝑛𝜃𝑔 = 𝑊𝑡12𝑡𝑎𝑛∅𝑐𝑜𝑠𝜃𝑝 = 617.33𝑁(𝑎𝑥𝑖𝑎𝑙 𝑙𝑜𝑎𝑑)

𝑊𝑟12 = 𝑊𝑡𝑡𝑎𝑛∅𝑐𝑜𝑠𝜃𝑔 = 61.61𝑁(𝑟𝑎𝑑𝑖𝑎𝑙 𝑙𝑜𝑎𝑑)

PERIPHERAL VELOCITY (V)

𝜋𝑑𝑛 𝜋 ∗ 0.048 ∗ 1400

𝑉= = = 3.51𝑚/𝑠
60 60

𝛱𝑑
𝑝 = = 𝛱𝑚
𝑁

where m = module, mm
d = pitch diameter, mm
p = circular pitch

As a general rule, bevel gears should have a face width B from 3 to 5 times the circular pitch p.
Let as assume 𝐵 = 10 × 𝑝

𝐵 = 10 ∗ 𝑚 = 62.83𝑚𝑚 = 60𝑚𝑚

Note: the average face on bevel gear is completed as follow

𝐷1𝑎𝑣 = 𝐷1 − 𝑏𝑐𝑜𝑠𝜃𝑔

= 48 − 72𝑐𝑜𝑠84.3 = 34.85𝑚𝑚

𝑝
𝑘𝑛𝑜𝑤 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑙𝑜𝑎𝑑 𝑓𝑜𝑟 𝑠𝑡𝑟𝑒𝑛𝑔ℎ 𝑊 ′ 𝑡12 = 60 × × 𝑛1 = 2350𝑁
𝜋𝐷1𝑎𝑣

2.4Geometry/dimensions of gears of bevel gear

We can determine all the important geometry of bevel gears previously we have determined

Pressure angle ∅ = 20 → 𝑎𝑠𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛

Module m=6mm→ 𝑎𝑠𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛

Number of teeth for pinion= 8

Number of teeth for gear= 80

Pitch circle diameter for pinion=48mm

Pitch circle diameter for gear=480mm

𝑎𝑑𝑑𝑒𝑛𝑑𝑢𝑚 = 𝑚 = 6𝑚𝑚

𝑑𝑒𝑑𝑒𝑛𝑑𝑢𝑚 = 1.25𝑚 = 7.5𝑚𝑚

𝑓𝑢𝑙𝑙 𝑑𝑒𝑝𝑡ℎ = 𝑎𝑑𝑑𝑒𝑛𝑑𝑢𝑚 + 𝑑𝑒𝑑𝑒𝑛𝑑𝑢𝑚 = 13.5𝑚𝑚

𝑑−𝑎
𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = = 0.75𝑚𝑚
2

𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑑𝑒𝑝𝑡ℎ = 2𝑚 = 12𝑚𝑚

Average pitch circle diameter of pinion

 𝐷1𝑎𝑣𝑔 = 𝐷1 − 𝐵𝑐𝑜𝑠𝜃𝑔

= 48 − 60𝑐𝑜𝑠84.5 = 42𝑚𝑚

Average pitch circle diameter of gear

𝐷2𝑎𝑣𝑔 = 𝐷2 − 𝐵𝑐𝑜𝑠𝜃𝑝

= 48 − 60𝑐𝑜𝑠5.7

= 420.3𝑚𝑚

1
𝑡𝑒𝑒𝑡ℎ
Diametric pitch = 𝑝𝑑 = 6 𝑚𝑚

𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑝𝑖𝑐𝑆ℎ = 𝜋𝑚 = 18.84𝑚𝑚

Addendum cone diameter of pinion

𝐷𝑜1 = 𝐷1 + 2𝑎𝑐𝑜𝑠𝜃𝑝

𝐷𝑜2 = 𝐷2 + 2𝑎𝑐𝑜𝑠𝜃𝑔

= 480 + 12𝑐𝑜𝑠84.5

= 481.2𝑚𝑚

Inside or dedundum cone diameter for pinion

𝐷𝑖1 = 𝐷1 − 2𝑑𝑐𝑜𝑠𝜃𝑝

= 48 − 2 × 1.5𝑐𝑜𝑠5.7

= 33𝑚𝑚

Inside or dedendum cone diameter of gear

𝐷𝑖2 = 𝐷2 − 2 × 𝑑𝑐𝑜𝑠𝜃𝑔

= 480 − 2 × 7.5𝑐𝑜𝑠84.3

= 478.5𝑚𝑚 = 479𝑚𝑚
Axial length of gear box

= 𝑏𝑐𝑜𝑠𝜃𝑝 = 60𝑐𝑜𝑠5.7

= 59.7𝑚𝑚 ≈ 60𝑚𝑚

Another important term for support and weight center is

-Rim -hub for a gear 1 and 2

-web

That parameter for gear 1 and 2 for gear 2

Hub length LH= 1.1 − 1.4𝑤𝐺 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑔𝑒𝑎𝑟

Taking Wg=16 and LH=

Hub diameter 𝐷ℎ = 2 ∗ 40 = 80𝑚𝑚

Rim thickness t=a+d=6+7.5=13.5mm

2.5AGMA STRESS EQUATIONS

Two fundamental stress equations are used in the AGMA methodology, one for bending stress
and another for pitting resistance (contact stress).

Bending stress

1 𝐾𝐻 ∗ 𝐾𝐵
𝜎 = 𝑊𝑡 𝐾𝑂 𝐾𝑉 𝐾𝑆 ∗
𝑏𝑚𝑡 𝑌𝐽

where
𝑊𝑡 is the tangential transmitted load, lbf (N)
𝐾𝑜 is the overload factor
𝐾𝑣 is the dynamic factor
𝐾𝑠 is the size factor
𝐹 (𝑏) is the face width of the narrower member, in (mm)
 𝐾𝑚 (𝐾𝐻) is the load-distribution factor
𝐾𝐵 is the rim-thickness factor
𝐽 (𝑌𝐽) is the geometry factor for bending strength (which includes root fillet
stress-concentration factor Kf )
(𝑚𝑡) is the transverse metric module

The equation for the allowable bending stress is

𝑆𝑡 𝑌𝑁
𝜎𝑎𝑙𝑙 = ∗
𝑆𝐹 𝑌𝛳 𝑌𝑍

Where
𝑺𝒕 is the allowable bending stress, (N/mm2)
𝐘𝐍 is the stress cycle factor for bending stress
(𝐘𝜭 ) are the temperature factors
𝒀𝒁 are the reliability factors
𝑺𝑭 is the AGMA factor of safety, a stress ratio

Reliability factor(𝑅) = 0.99

number of cycles(𝑁) = 109 𝑐𝑦𝑐𝑙𝑒𝑠

overload factor(𝐾0 ) = 1(uniform uniform)

transverse metric module(𝑚𝑡) = 5mm

the rim-thickness factor (𝐾𝐵) =assume 𝑚𝑏 ≥1.2 so, 𝑘𝐵 =1

For temperature upto 1200C KT(Yϴ)=1

design factor(𝑛𝑑 ) = 2

quality number(𝑄𝑣 ) = 6, 𝑔𝑟𝑎𝑑𝑒 2

Dynamic factor(Kv)
 𝐴 + √200𝑉 𝐵
𝐾𝑣 = ( )
𝐴

𝐵 = 0.25(12 − 𝑄𝑉 )2/3 = 0.25 ∗ (12 − 6)2/3 = 0.825

𝐴 = 50 + 56(1 − 𝐵) = 50 + 56(1 − 0.825) = 59.8

59.77 + √200 ∗ 3.37 0.825

𝐾𝑣 = ( ) = 1.35
59.77

Reliability factor(YZ)=1

Bending strength stress cycle factor YN

(YN)P = 1.3558 N −0.0178= 1.3558 (109)−0.0178=0.938

(YN)G = 1.3558 N −0.0178= 1.3558 (109/5)−0.0178=0.965

Pitting resistance stress cycle factor ZN

(ZN) p=2.466(109)-0.056 =0.773

(ZN)G=2.466(109/5)-0.056 =0.8455

𝐿𝑜𝑎𝑑 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟(𝐾𝐻) = 1 + 𝐶𝑚𝑐(𝐶𝑝𝑓 ∗ 𝐶𝑝𝑚 + 𝐶𝑚𝑎 ∗ 𝐶𝑒)

𝐶𝑝𝑚 = 𝐶𝑒 = 𝐶𝑚𝑐 = 1

𝐶𝑚𝑎 = 𝐴 + 𝐵𝐹 + 𝐶𝐹 2 = 0.127 + 0.0158 ∗ (2.47) + −0.930 ∗ (10−4 ) ∗ (2.472 )

𝐶𝑚𝑎 = 0.165

𝐹 2.47
𝐶𝑝𝑓 = − 0.0375 + 0.0125𝐹 = − 0.0375 + 0.0125 ∗ 2.47 = 0.063
10𝑑 10 ∗ 3.54

𝐾𝐻 = 1 + 1(0.063 ∗ 1 + 0.165 ∗ 1) = 1.228

Geometry factor(YJ)

(YJ) p= 0.325 (YJ) G= 0.425

For carburized and hardened steel grade 2 material AGMA strength (𝑆𝑡) = 65000𝑝𝑠𝑖 =
448.16𝑁/𝑚𝑚2

For carburized and hardened steel allowable contact stress (SC) is 225000𝑝𝑠𝑖

= 1551.32𝑁/𝑚𝑚2

PINION TOOTH BENDING.

1 K𝐻∗K𝐵
Pinion tooth bending stress(σ)=WtK0KVKSbm𝑡 ∗ Y𝐽

1.228∗1
σ=2225.9N*1*1.35*1 0.0628∗0.005∗0.325 =36.16N/mm2

𝑆𝑡 𝑌𝑁
⁄𝐾 𝐾 448.16𝑀𝑃𝑎∗0.938
𝑇 𝑅
Bending factor of 𝑠𝑎𝑓𝑒𝑡𝑦 (𝑆𝐹 ) = = = 11.62
𝜎 36.16𝑀𝑃𝑎

GEAR TOOTH BENDING

Using same material ,heat treatment and carburizing ,the load induced bending stress is in ratio
of 𝑌𝐽𝑃/𝑌𝐽𝐺.

𝐹𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒, 𝑌𝐽𝑃 = 0.325 , 𝑌𝐽𝐺 = 0.425 𝑠𝑜 𝑌𝐽𝑃/𝑌𝐽𝐺 = 0.325/0.425 = 0.765

𝑌𝐽𝑃
(𝜎)𝐺 = (𝜎)𝑃 = 36.16 ∗ 0.765 = 27.66𝑁/𝑚𝑚2
𝑌𝐽𝐺

𝑆𝑡 𝑌𝑁
⁄𝐾 448.16𝑀𝑃𝑎∗0.938
𝑅
Bending factor of safety(SF) = = = 15.2
𝜎 27.66𝑀𝑃𝑎

THE FUNDAMENTAL EQUATION FOR PITTING RESISTANCE (CONTACT STRESS) IS

K𝐻 Z𝑅
σc=ZE√W𝑡 K𝑜K𝑣K𝑠 d𝑤1b Z𝐼

where Wt, Ko, Kv, Ks, Km, F, and b are the same terms as defined above.
The additional terms are
Cp (Z E) is an elastic coefficient, √lbf/in2 (√N/mm2)
Cf (Z R) is the surface condition factor
dP (dw1) is the pitch diameter of the pinion, in (mm)
I (Z I) is the geometry factor for pitting resistance

The equation for the allowable contact stress 𝜎𝑐, 𝑎𝑙𝑙 is

𝑆𝑐 𝑍𝑁 𝑍𝑊
𝜎𝑐, 𝑎𝑙𝑙 = ∗
𝑆𝐻 𝑌𝛳 𝑌𝑍

where
Sc is the allowable contact stress, lbf/in2 (N/mm2)
Z N is the stress cycle life factor
ZW are the hardness ratio factors for pitting resistance
Yθ are the temperature factors
YZ are the reliability factors
SH is the AGMA factor of safety, a stress ratio


For carburized and hardened steel allowable contact stress(SC) from the table is
225000psi=1551.32N/mm2
𝑠𝑖𝑛𝜙𝑐𝑜𝑠𝜙 𝐺 𝑀
 𝐺𝑒𝑜𝑚𝑒𝑡𝑟𝑦 𝑓𝑎𝑐𝑡𝑜𝑟(𝑍𝐼) = ∗ 𝑀𝐺+1
2𝑀𝑁

𝑀𝐺 = 5, 𝑓𝑜𝑟 𝑏𝑒𝑣𝑒𝑙 𝑔𝑒𝑎𝑟 𝑀𝑁 = 1

𝐶𝑂𝑆 20 ∗ 𝑆𝑖𝑛20 5
𝑍𝐼 = ∗ = 0.134 (𝑓𝑜𝑟 𝑝𝑖𝑡𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑖𝑠𝑡𝑎𝑛𝑐𝑒)
2 5+1
 AGMA specifies the value of surface condition factor(ZR) greater than unity, so we
assume ZR=1.2
 As the selected material is same for both gear and pinion the value of hardness ratio
factor(ZW) is 1
HBP=brinell hardness of pinion
HBG=brinell hardness of gear
 From the table elastic coefficient(ZE) for steel = 191√𝑀𝑝𝑎

Pitting resistance (contact stress) for pinion

 1.228∗1.2
σc=191√𝑀𝑝𝑎√2225.9𝑁 ∗ 1 ∗ 1.35 ∗ 1 ∗ 90∗62.83∗0.134 = 461.73N/mm2

 contact factor of safety(SH)

𝑆𝑐 𝑍𝑁 𝑍𝑊
 𝑆𝐻 = 𝜎
𝐶 𝑌𝛳 𝑌𝑍

1551.32 ∗ 0.773 ∗ 1
𝑆𝐻 = = 2.6
461.73 1∗1
Pitting resistance (contact stress) for gear

The hardness of the gear and pinion are the same. Thus (K S )G = (K S )P = 1 , the contact stress
on the gear is the same as the pinion.

So,𝜎𝑐 = 461.73𝑁/𝑚𝑚2

contact factor of safety(𝑆𝐻)

1551.32 ∗ 0.8455 ∗ 1
𝑆𝐻 = = 2.84
461.73 1∗1

2.6FORCE ANALYSIS OF PINION AND GEAR

This tangential load is really the useful component, because the radial component serves no
useful purpose. It does not transmit power.

60 000H
Wt = Πdn

Where 𝑊𝑡 = 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑 𝑙𝑜𝑎𝑑, 𝑘𝑁

𝐻 = 𝑝𝑜𝑤𝑒𝑟, 𝑘𝑊
𝑑 = 𝑔𝑒𝑎𝑟 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝑚𝑚
𝑛 = 𝑠𝑝𝑒𝑒𝑑, 𝑟𝑒𝑣/𝑚𝑖𝑛

60 000 ∗ 6KW
Wt = = 1704.5N
Π ∗ 0.048mm ∗ 1400rpm

Peripheral velocity (V)

𝜋𝑑𝑛 𝜋 ∗ 0.048 ∗ 1400 𝑚

𝑉= = = 3.5166
60 60 𝑠

Dynamic factor(Kv)

𝐴 + √200𝑉 𝐵
𝐾𝑣 = ( )
𝐴
 𝐵 = 0.25(12 − 𝑄𝑉 )2/3 = 0.25 ∗ (12 − 6)2/3 = 0.825

𝐴 = 50 + 56(1 − 𝐵) = 50 + 56(1 − 0.825) = 59.8

54.816 + √200 ∗ 3.5166 0.9145

𝐾𝑣 = ( ) = 1.356
59.77

Reliability factor(YZ)=1

Bending strength stress cycle factor YN

(YN)P = 1.6831 N −0.0823 = 1.6831 (109)−0.0823 = 0.219583

(YN)G = 1.6831 N −0.0823= 1.6831 (109/5)−0.0823=0.192342

Pitting resistance stress cycle factor ZN

(ZN) p=2.466(109)-0.056 =0.32573

(ZN)G=2.466(109/5)-0.056 =0.32573

𝐿𝑜𝑎𝑑 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟(𝐾𝐻) = 1 + 𝐶𝑚𝑐(𝐶𝑝𝑓 ∗ 𝐶𝑝𝑚 + 𝐶𝑚𝑎 ∗ 𝐶𝑒)

𝐶𝑝𝑚 = 𝐶𝑒 = 𝐶𝑚𝑐 = 1

𝐶𝑚𝑎 = 𝐴 + 𝐵𝐹 + 𝐶𝐹 2 = 0.127 + 0.0158 ∗ (2.47) + −0.930 ∗ (10−4 ) ∗ (2.472 )

𝐶𝑚𝑎 = 0.165

𝐹 2.47
𝐶𝑝𝑓 = − 0.0375 + 0.0125𝐹 = − 0.0375 + 0.0125 ∗ 2.47 = 0.063
10𝑑 10 ∗ 3.54

𝐾𝐻 = 1 + 1(0.063 ∗ 1 + 0.165 ∗ 1) = 1.228

Geometry factor(YJ)

(YJ) p= 0.325 (YJ) G= 0.425

For carburized and hardened steel grade 2 material AGMA strength (𝑆𝑡) = 65000𝑝𝑠𝑖 =
448.16𝑁/𝑚𝑚2
For carburized and hardened steel allowable contact stress (SC) is 225000𝑝𝑠𝑖

= 1551.32𝑁/𝑚𝑚2

PINION TOOTH BENDING.

1 K𝐻∗K𝐵
Pinion tooth bending stress(σ)=WtK0KVKSbm𝑡 ∗ Y𝐽

1.228∗1
𝜎 = 1704.5 𝑁 ∗ 1 ∗ 1.16 ∗ 1 0.0628∗0.005∗0.325 = 155.4N/mm2

𝑆𝑡 𝑌𝑁
⁄𝐾 𝐾 448.16𝑀𝑃𝑎∗0.938
𝑇 𝑅
Bending factor of 𝑠𝑎𝑓𝑒𝑡𝑦 (𝑆𝐹 ) = = = 2.71
𝜎 155.4𝑀𝑃𝑎

GEAR TOOTH BENDING

Using same material ,heat treatment and carburizing ,the load induced bending stress is in ratio
of 𝑌𝐽𝑃/𝑌𝐽𝐺.

𝐹𝑟𝑜𝑚 𝑓𝑖𝑔𝑢𝑟𝑒, 𝑌𝐽𝑃 = 0.325 , 𝑌𝐽𝐺 = 0.425 𝑠𝑜 𝑌𝐽𝑃/𝑌𝐽𝐺 = 0.325/0.425 = 0.765

𝑌𝐽𝑃
(𝜎)𝐺 = (𝜎)𝑃 = 155.4 ∗ 0.765 = 118.881𝑁/𝑚𝑚2
𝑌𝐽𝐺

𝑆𝑡 𝑌𝑁
⁄𝐾 𝐾 448.16𝑀𝑃𝑎∗0.938
𝑇 𝑅
Bending factor of safety(SF) = = = 28.316𝑀𝑝𝑎
𝜎 118.9𝑀𝑃𝑎

Pitting resistance (contact stress) for pinion

1.228∗1.2
σc=191√𝑀𝑝𝑎√11 129.7𝑁 ∗ 1 ∗ 1.16 ∗ 1 ∗ 90∗62.83∗0.134 = 957.1N/mm2

 contact factor of safety(SH)

𝑆𝑐 𝑍𝑁 𝑍𝑊
 𝑆𝐻 = 𝜎
𝐶 𝑌𝛳 𝑌𝑍

1551.32 ∗ 0.773 ∗ 1
𝑆𝐻 = = 1.3
957.1 1∗1

Pitting resistance (contact stress) for gear

The hardness of the gear and pinion are the same. Thus (K S )G = (K S )P = 1 , the contact stress
on the gear is the same as the pinion.

So,𝜎𝑐 = 957.1𝑁/𝑚𝑚2

contact factor of safety(𝑆𝐻)

1551.32 ∗ 0.8455 ∗ 1
𝑆𝐻 = = 1.37
957.1 1∗1

2.7SHAFT DESIGN
Shaft is rotating machine which is used to transmit power from one place to another. In order to
transfer power from one shaft to another ,the various members such as gears,pulleys and etc are
mounted on it. Due to these members the force exerted on the shaft causes bending.

Material Used for Shafts

The material used for shafts should have the following properties :

 It should have high strength.

 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties.
 It should have high wear resistant properties.
 SHAFT MATERIAL SPECIFICATION
45C8 carbon steel is selected as shaft material due to its better mechanical properties.
The shaft is made of 45 C 8 steel having ultimate tensile stress of 700 MPa and
a ultimate shear stress of 500 MPa.
Assuming a factor of safety as 3
We know that the allowable tensile stress,
σult.tensile 700MPa
σt = = = 233.3MPa
FOS 3

And allowable shear stress,

 τ
ult 500MPa
τall = FOS = = 166.67MPa
3

2.7.1SHAFT CALCULATIONS
Shafts are subjected to axial, bending and torsional stresses. So , to design shaft we have to
calculate these parameters.

2.7.2INPUT SHAFT
Input data

Power to be transmitted is 6 KW and speed is 1500rpm

𝜃 𝑝 = 5.7 , 𝜃𝐺 = 84.3 ,∅ = 20

Pitch diameter at each gear

𝐷1 = 48𝑚𝑚 𝑓𝑜𝑟 𝑔𝑒𝑎𝑟 1

𝐷2 = 480𝑚𝑚 𝑓𝑜𝑟 𝑔𝑒𝑎𝑟 2

𝐷1𝑎𝑣 = 𝐷1 − 𝐵𝑐𝑜𝑠𝜃𝐺 = 42

𝐷2𝑎𝑣 = 𝐷2 − 𝐵𝑐𝑜𝑠𝜃𝑝 = 420.3

Pitch line velocity

𝜋𝐷1𝑎𝑣𝑛 3.516𝑚
𝑉12 = =
60 𝑠

𝑝 6000
𝑤 𝑡12 = = = 1950𝑁𝑚
𝑣12 3.0772

𝑤𝑟12 = 𝑤12𝑡𝑎𝑛∅𝑐𝑜𝑠𝜃𝑔 = 70.5

 𝐷1𝑎
𝐶𝑂𝑈𝑃𝐿𝐸 = 𝑀1 = ∗ 𝑊 = 0.021 ∗ 706.23 = 14.83
2

Using stating static equation equilibrium

∑𝑚 = 0

∑𝑚1 − 𝑤12 = 0

∑𝐹𝑥 = 0 → 𝑊𝑟12 − 𝐴𝑦 = 0

𝐴𝑦 = 𝑊𝑟12 = 70.5𝑁

∑𝑓𝑥 = 0 → 𝑊𝑎12 + 𝐴𝑥 = 0

𝐴𝑥 = 𝑊𝑎12 = 706.23

Shear force and bending moment in shaft one

For the interval between 0 ≤ 𝑥 ≤ 100(for x-y plane)

∑𝑓𝑦 = 0

70.5 − 𝑣 = 0

𝑣 = 70.5𝑁

For the moment at the interval between 0 ≤ 𝑥 ≤ 100

∑𝑀𝑏 = 0

𝑀1 − 𝐴𝑦 × 𝑥 + 𝑀𝑏 = 0

100
𝑀1 − 𝐴𝑦 ∗ 𝑥 + 𝑀𝑏 = 070.5 × − 14.83
1000

= −7.78𝑁𝑚 𝑎𝑡 𝑥 = 100

For x-z plane

∑𝑓𝑦𝑚𝑏 = 0
 𝑀1 − 𝐴𝑦𝑥 + 𝑀𝑏 = 0

𝑀𝑏 = 𝐴𝑦𝑥 − 𝑀1

100
= 1950 ∗ − 14.83
1000

= 180.17𝑁𝑚

Resultant bending moment

𝑀𝐵 = √(𝑀𝐵𝑉 2 ) + (𝑀𝐵𝐻 2 )

MB = √7.82 + 1802 = 180.16

Equivalent bending moment

Pd 2
Me = √(K m ∗ M + ) + (K t ∗ T)2
8

(9.56 + 6.123𝑑 + 𝑑 2
=88.27√

2𝛱𝑁
𝑃 = 𝑇𝑊 = 𝑇 ∗
60

𝑇 = (60 ∗ 7.5𝐾𝑊)/(2𝛱 ∗ 715𝑅𝑃𝑀) = 100.2𝑁𝑚

60 000 ∗ 7.5KW
Wt = = 2.226KN = 2225.9N
Π ∗ 90mm ∗ 715rpm

𝑊𝑟 = 𝑊𝑡 ∗ 𝑡𝑎𝑛20

= 2225.9𝑡𝑎𝑛20 = 810.16𝑁

Resultant bending moment

MB = √(MBV 2 ) + (MBH 2 ) = √(89.0362 ) + (32.412 ) = 94.75Nm

Considering that the shaft experience gradually applied or steady load from the table K m =1.5 and
Kt = 1

The equivalent twisting moment will be given by the following equation

Te = √(K m ∗ M)2 + (K t ∗ T)2

Te = √(1.5 ∗ 94.75)2 + (1 ∗ 100.2)2

Te = 173.895Nm

The equivalent bending moment

Pd 2
Me = √(K m ∗ M + ) + (K t ∗ T)2
8

Me = √(180.16 ∗ 1.5 ∗ 94.75d)2 + (1 ∗ 100.2)2

Me =88.27√(9.58 + 6.123𝑑 + 𝑑^2

Considering bending moment

Π
Mmax = ∗ σt ∗ d3
32

3 32 ∗ 𝑀𝑒
𝑑=√
𝛱 ∗ 𝜎𝑡

= 𝑏𝑦 𝑡𝑟𝑖𝑎𝑙 𝑎𝑛𝑑 𝑒𝑟𝑟𝑜𝑟 𝑚𝑒𝑡ℎ𝑜𝑑 𝑜𝑟 𝑏𝑦 𝑢𝑠𝑖𝑛𝑔 𝑏𝑦 𝑎𝑙𝑔𝑜𝑟𝑖𝑡ℎ𝑚 𝑛𝑢𝑚𝑒𝑟𝑖𝑐𝑎𝑙 𝑚𝑒𝑡ℎ𝑜𝑑 𝑤𝑒 𝑐𝑎𝑛 𝑠𝑜𝑙𝑣𝑒 𝑓𝑜𝑟 𝑡ℎ𝑒 𝑎𝑏𝑜𝑣𝑒

𝑑 = 17.5

From The standard diameter of shaft

Taking the largest one the diameter of shaft will be 𝑑 = 20𝑚𝑚

 2.7.3Output shaft
Input data

Power to be transmitted is 7.5KW and speed is 28.6rpm

2𝛱𝑁
𝑃 = 𝑇𝑊 = 𝑇 ∗
60

𝑇 = (60 ∗ 7.5𝐾𝑊)/(2𝛱 ∗ 29𝑅𝑃𝑀) = 2504.25𝑁𝑚

60 000 ∗ 7.5KW
Wt = = 11.13KN = 11 129.7N
Π ∗ 450mm ∗ 28.6rpm

𝑊𝑟 = 𝑊𝑡 ∗ 𝑡𝑎𝑛20

= 11 129.7𝑡𝑎𝑛20 = 4050.9𝑁

First we have the listed below data

𝑊12 = 1950𝑁𝑚

𝑊𝑎12 = 706.23𝑁

𝑊𝑟12 = 70.5𝑁

The couple force for gear 2

 𝐷𝑎12
M2=𝑊𝑎12 × 2

210.23
M2= 706.23 × 1000

M2=148.41Nm

Using static equilibrium equation

∑𝑀𝑐 = 0

𝑀2 + 𝑊𝑟12 ∗ 0.08 − 𝐵𝑦(0.125) = 0

148.41 + 70.5(0.081) − 𝐵𝑦(0.125) = 0

𝐵𝑦 = 1232.4𝑁

∑𝐹𝑦 = 0

𝐶𝑦 + 𝐵𝑦 − 𝑊𝑟12 = 0

𝐶𝑦 + 1232.4 − 70.5 = 0

𝐶𝑦 = −1161.9

∑𝐹𝑥 = 0

𝑊𝑎12 − 𝐵𝑥 = 0

𝐵𝑥 = 706.23𝑁

Shear force diagram and bending moment

For x-y plane

 ∑𝑓𝑦 = 0

𝐶𝑦 + 𝑣 = 0

𝑣 = −1161.9𝑁(Shear force)

𝑀𝑏 + 𝐶𝑦𝑥 = 0

𝑀𝑏 = −1161.9𝑥(bending moment)

For section 2 →0.08 ≤ 𝑥 ≤ 0.125

∑𝑓𝑦 = 0

𝑐𝑦 + 𝑊𝑟12 + 𝑣 = 0

𝑣 = −1161.9 − 70.5

Shear force = −1161.9

𝑀𝑏 − 𝑀2 + 𝐶𝑦𝑥 + 𝑊𝑟12(𝑥 − 0.08) = 0

𝑀𝑏 − 148.41 + 1161.9𝑥 + 70.5(𝑥 − 0.08) = 0

𝑀𝑏 = −1232.4𝑥 + 154.05

x V M

0 -1161.9 0

0.08 -1161.9 -92.952

0.08 -1232.4 55.458

0.125 -1232.4 0

For x-z planes

Using static equilibrium moments

∑𝑓𝑦 = 0

𝐶𝑧 + 𝐵𝑧 − 𝑊12 = 0

𝐶𝑧 = 𝐵𝑧 − 𝑊12

= −1248 + 1950 = 702

For Section 1

𝑐𝑦 − 𝑣 = 0

𝑣 = 702

∑𝑀𝑜 = 0

𝑀𝑏 = 702𝑥

For section 2

∑𝑓𝑧 = 0

702 − 1950 − 𝑣 = 0

𝑣 = 702 − 1950 = −1248

∑𝑀𝑏 + 1950(𝑥 − 0.08) − 702𝑥 = 0

𝑀𝑏 − 156 + 1248𝑥 = 0

𝑀𝑏 = −1248𝑥 + 156

x V M

0 702 0

0.08 702 56.16

0.08 -1248 56.16

0.125 -1248 0

Resultant bending moment

MB = √(MBV 2 ) + (MBH 2 ) = √56.162 + 92.9522 = 108.6Nm

Considering that the shaft experience gradually applied or steady load from the table K m =1.5 and
Kt = 1

The equivalent twisting moment will be given by the following equation

Te = √(K m ∗ M)2 + (K t ∗ T)2

Te = √(1.5 ∗ 473.7)2 + (1 ∗ 2504.25)2

Te = 2603.12Nm

The equivalent bending moment

Me = √(K m ∗ M + pd/8)2 + (K t ∗ T)2

Me = 88.2 + √24.98 + 3.69𝑑 + 𝑑2

Considering bending moment

3 32 ∗ 𝑀𝑚𝑎𝑥 3 32 ∗ 108.67
𝑑=√ =√
𝛱 ∗ 𝜎𝑡 𝛱 ∗ 233.33

The standard shaft diameter selected is 𝑑 = 40𝑚𝑚

Considering torsion moment

Π
Te = ∗ τ ∗ d3
16 all

𝑑 = 38𝑚𝑚

Taking the largest one the diameter of shaft d will be 40𝑚𝑚

2.8Bearing selection
Selection of bearing is based on the catalog load rating C10 which is often referred to as a Basic
Dynamic Load Rating, or sometimes just Basic Load Rating.

Bearing rating life -Is the number of revolution or hours of operation, at constant speed, in such
a way that 90% of the bearings tested (from the same group) will complete or exceed before the
first evidence of failure develops. This is known as L10 life.

According to ABMA 𝐿10 = (𝐿𝑅𝑛𝑅 60)

For ball bearings and spherical bearings manufactured by Timken:

L10 = 500 (hours) x 33.33 (rpm) x 60 = 106 = 1 million revolutions

 Reliability = 90%
 a for ball bearing = 3
 Desired(expected) Life of bearing = 12 000hr(Assuming Machines working 10 hours per
day, 240days per year 5year total working life)

2.8.1 Bearing selection for input shaft

1⁄
L n 60 a
C10 = FD (LD nD60)
R R

Where FD = normal load = 1.185𝐾𝑁

LD = life bearing = 12 000𝐻𝑟

nd = shaft speed = 1400𝑟𝑝𝑚

 1⁄
12 000x1400rpmx60 3
C10 = 1.185KN ( ) = 9.302KN
106

Now from the catalogue of bearing (table of bearing standard) we can choose a single row deep
groove ball bearing and bearing number of 204, from this table we have

Based on C10 = 10KN dimension and basic load rating for single row deep groove ball bearing
72

Table 2 bearing parameter for input shaft bearing number of 204

C10(dynamic C(static Bore(mm) OD(mm) Width(mm)

load
Bearing load)
capacities
number

204 10KN 6.55 20 47 14

2.8.2BEARING SELECTION FOR OUTPUT SHAFT

Where FD = normal load = 1704.5𝑁

nd = shaft speed = 29𝑟𝑝𝑚

1⁄
12 000x 29rpmx60 3
C10 = 1704.5N ( ) = 16.3KN
106

Based on C10 = 27.5KN dimension and basic load rating for ball bearing 02 series 72

Table 3 bearing parameter for intermediate shaft bearing number of 407

Bearing C10(dynamic C(static Bore(mm) OD(mm) Width(mm)

number load) load)

210 27.5KN 21.2KN 50 90 20

 2.9 DESIGN OF KEY
For preventing relative motion or rotation between shaft and gear we have to use key. There
are different types of keys but for our design sunk key is better than others in case of
directional suitability of key way and cost as well assize reduction. There are two types of sunk
key. Those are square and rectangular sunk key. Square sunk is better than the rectangular in
case of crushing stress. Therefore we choose square sunk key.

𝑑
Now 𝑇=𝐹+2 where T= torque transmitted by the shaft

F=tangential force acting at the circumference of the shaft

D=diameter of shaft

l=length of the key

b=width of the key

h=thickness of the key

As=area of shearing

𝐴𝑠 = 𝑏 ∗ 𝑙

Ac=area of crushing

ℎ
Ac = 𝑙 + 2

𝛿𝑐 𝑎𝑛𝑑 𝜏 Crushing and Shear stresses for the material of the key respectively.

The standard dimension for square key is

𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 𝑑

h= =
4 4

𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡 𝑑
b= =4
4
 l = 1.5d

While we are designing the, we consider two stresses those can be applied on the key and we
will check for safe limit. There are crushing stresses and shearing stresses.

Thus, steel with permissible crushing stresses of, 𝛿𝑐 = 200Mpa and permissible shearing stress
of,

𝛿𝑐
𝜏= = 100Mpa can be selected for the keys.
2

2.9.1 DESIGN OF KEY – 1

D1=𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 − 1 = 20𝑚𝑚

Wt12= 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑠ℎ𝑎𝑓𝑡 − 1 = 1950𝑁

𝑛1 = 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 2

𝑙1 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑘𝑒𝑦 − 1 = 60𝑚𝑚

𝛿𝑐 𝑎𝑛𝑑 𝜏 Crushing and Shear stresses respectively.

𝑑 20
𝑏1 = = = 5 Standard 𝑏1 = 5
4 4

𝑑 20
ℎ1 = = = 5 𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 ℎ1 = 5
4 4

Check for shearing

Allowable shear stress =33.3Mpa

𝑓 1950
𝜏= = = 6.5𝑀𝑝𝑎
𝐴𝑠 60∗5

𝜏 = 6.5𝑀𝑝𝑎 Which is less than allowable stress shear, hence our dimension is safe

Checking for crushing

Allowable crushing strength

𝛿𝑎𝑙𝑙 = 66.67𝑀𝑝𝑎
 𝐹 1950∗2
𝛿𝑐 = 𝐴𝑐 = = 13𝑀𝑝𝑎
60∗5

𝛿𝑐 = 13𝑀𝑝𝑎 Which is less than allowable shear stress, hence the dimension is safe.

2.9.2 Design of key -2

D1=𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡 − 1 = 40𝑚𝑚

Wt12= 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙 𝑓𝑜𝑟𝑐𝑒 𝑜𝑛 𝑠ℎ𝑎𝑓𝑡 − 2 = 1950𝑁

𝑛1 = 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦 = 2

𝑙1 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑘𝑒𝑦 − 2 = 40𝑚𝑚

𝛿𝑐 𝑎𝑛𝑑 𝜏 Crushing and Shear stresses respectively.

𝑑 40
𝑏1 = = = 10 Standard 𝑏1 = 10
4 4

𝑑 40
ℎ1 = = = 10 Standard h1 =10
4 4

Check for shearing

Allowable shear stress =33.3Mpa

𝑓 1950
𝜏 = 𝐴𝑠 = 40∗10 = 4.87𝑀𝑝𝑎

𝜏 = 4.87𝑀𝑝𝑎 Which is less than allowable stress shear, hence our dimension is safe.
Checking for crushing

Allowable crushing strength

𝛿𝑎𝑙𝑙 = 66.67𝑀𝑝𝑎

𝐹 1950∗2
𝛿𝑐 = 𝐴𝑐 = = 9.75𝑀𝑝𝑎
40∗10

𝛿𝑐 = 9.75𝑀𝑝𝑎 Which is less than allowable shear stress, hence the dimension is safe.

The selected material for keys are iron steel with

 Crushing stress 𝛿𝑐 = 200𝑀𝑝𝑎

Shearing strength 𝜏𝑦 = 100𝑀𝑝𝑎

Tensile strength 𝜏𝑠 = 330𝑀𝑝𝑎

2.10 Design of gear housing box

Housing is the over cover of the motion system by some convenient cover. It protects the
internal parts of the system from some external damage factors. It is also used for saving the
lubricant that are beyond in on motion it carries the system and motion control is within. It is
also called gear box casing. It needs critical desi1gn why become the gear box elements which
needs safe places for better and proper operation.

Gear box casing are made from many material based on the regnired mechanical properties.
Many gear box casing are made from cast iron. Because cast iron has the following properties.

 The ability to observe mechanical properties

 Corrosion resistance
 Structural regality
 High strength in compression
 High machinability
 Relatively cheap

Due to the above mechanical properties, we have to select cast iron casing for this gear box.

So that the material selected is,

Fc 200 that takes minimum tensile strength of 200Mpa

Dimension of gear box housing

Dimension of gear box are based on tumble rule. This is given as follows:

For s wall thickness in mm of the gear box

 Material: CL casting
 Non case hardness gears = 0.007𝑙 + 6𝑚𝑚

Case hardness gears = 0.01𝑙 + 6𝑚𝑚

 Material: steel casting

Non case hardness gears = 10.005𝑙 + 4𝑚𝑚

Case hardness gears = 0.007𝑙 + 4𝑚𝑚

 Material: Welded construction

Non case hardness gears = 10.004𝑙 + 4𝑚𝑚

Case hardness gears = 0.005𝑙 + 4𝑚𝑚

Where l is the largest diameter of the housing

For cast iron casing and case hardened gears, from the above expression,

𝑠 = 0.01𝑙 + 6𝑚𝑚 = 0.01 ∗ 532 + 6 = 11.5

𝑠 = 11.5𝑚𝑚 𝑤ℎ𝑖𝑐ℎ 𝑖𝑠 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑤𝑎𝑙𝑙

Top cover thickness, Sc = 0.8𝑠 = 0.85 ∗ 11.5 = 9.25

Flange cover bolt diameter, 𝑏𝑑 = 1.5 ∗ 𝑠 = 1.5 ∗ 11.5 = 17.25𝑚𝑚

Therefore general standard bolt is M18 bolts

Bolt spacing: 6𝑏𝑑 = 6 ∗ 18 = 110𝑚𝑚

1
Foundation bolt diameter: 𝑑𝑓𝑏 = (2𝑇)2 ≥ 12𝑚𝑚

1
𝑑𝑓𝑏 = (2 ∗ 3.62 ∗ 961.1)2 = 19.2

For this case take the standard bolts, M20 bolts

Thickness of the foundation flange

 𝑠𝑓𝑓 ≥ 1,5𝑑𝑓𝑏 = 1.5 ∗ 20 = 30

𝑠𝑓𝑓 = 30𝑚𝑚

CHAPTER THREE

3.1LUBRICATION

The purpose of lubrication is:

 Reducing the friction between mating part

 Reduce gear failure
 Removing heat which is generated during operation

Example: wearing of surfacing tooth may be prevented

Gear reducers are lubricated either by immersion or forced lubrication. But, for our design
immersion lubrication are selected because high cost of forced (spray) lubrication.

Immersion lubrication is once or more wheel dip in lubricate stored in the bottom of the
housing is limited to gear speed of 12m/s to 14m/s.

3.2Selection of lubrication for gear

Selection of lubrication is based on the peripheral velocity, type of application and operating.

SAE30, 40, 50, 60 and 80… are being recommended for low lubrication and high temperature
operation synthetic oils are used

3.3 Lubrication for bearing

The liquids lubrication usually used in bearing are minerals oils. Minerals oil is
commonly used since it has cheapness and stability properties.

3.4 Properties of lubrication

1) Viscosity: it is the measure of degree of fluidity.

  Oil is able to form retained and other resistance to shearing a buffer under heat and
pressure.
 The greater heat pressure, the greater viscosity required of lubrication to prevent
thinning and squeezing.

2) Oinked: is an unbent property of the lubricant and the bearing surface in contact. It is
measure of lubricant quality.

3) Density: useful in changing the kinematic viscosity to absolute viscosity.

Absolute viscosity ≤ kinematic viscosity

𝑘𝑔
The density of most common 860 to 950860 𝑡𝑜 950 𝑚3

𝑘𝑔
For our design the average values taken to be 900 𝑚3

Conclusion

The design and fabrication of gear box was carried out successfully according to our project
plan and specification. Based on given gear ratio we design the single stage speed reduction
gear box, since the power is not large and speed is moderately high the single stage speed
reduction is performed for our project. It is described, force analysis and inner stress on shaft,
gear and other parts of gear box is calculated. The bending moment and shear force are
calculated.

After we complete this project, we have really gained skills and knowledge in this field.

Finally the experience we have obtained though out this project will certainly help us to be a
‘creative engineer’ in the future.
Recommendation

We recommended that when design the single stage bevel gear box first, to know the design of
gear is depending on beam strength, pitting, and tooth bending stress. Also material selection
up on availability, cost and weight, factor of safety, on bending and on fatigue stress, life
expectance, design of shaft, selection of bearing, gear housing and some parts of mechanical
design should have be considered.
 REFERENCE
1. Shigley’s Mechanical Engineering Design, Author by budynas-Nisbleff.
2. Design of machine elements, 8th edition by M.F.SPOTTS.T.L.SHOUP.L.L HONRBERGER.

3. Design of machine of element 2nd edition by V.B.Bhardari. Tata McGraw-Hill publisher

4. Standard hand book of Machine design, 3rd Edition, Authorized by McGRAW-HILL.