MECHANICAL DRIVES &

TRANSMISSION

1. SHAFT
2. KEYS & COUPLING
3. CHAIN & BELTS
4. GEARBOX
SHAFT
Shaft is rotating m/c element used to transmit power
from one place to another
AXLE
Axle is a stationery m/c element used for
transmission of bending moment only eg: idler shaft
Spindle
Spindle is a short shaft
STD size
25 mm to 60 mm with 5 mm steps
60 to 110 with 10 mm steps and so on
STRESSES IN SHAFT
•Shear stress : due to torsional load
•Bending stress : due to forces acting upon
m/c elements like gears, pulleys etc
•Combined of both above
Material for shaft :
MS, Alloy steel using nickle, chrome & chrome
vanadium for high strength
 Governing Equation for shaft
P = 2πNT / 4500

P ∞ N and T
Where, P= power ( HP) of shaft
N= speed in rpm
T= twisting moment

T =

T∞
Fs = shear stress for shaft material ( depends on material)
d = shaft dia.
KEYS & COUPLINGS
• KEY
A piece of MS inserted between shaft and
pulley. Keys are temporary fastenings and are
subjected to crushing and shearing stress.
TYPE
• Rectangular & square keys
• Gib Head keys ( Head at one end )
• Feather keys ( key fastened with shaft )
• Wood ruff key ( easily adjustable , Tilting keys)
• Splines
Square Key
Provided half in the keyway of shaft &
half in keyway of hub or boss of pulley
Governing equation:
w = t = D/4
SPLINES
The spline shaft are used when the force
to be transmitted is large in proportion
to the size of shaft usually 4,6,10,16
splines are used.
 COUPLINGS
• SHAFT COUPLING
A coupling is a device used to connect two shafts together at
their ends for the purpose of transmitting power.
• PURPOSE OF SHAFT COUPLING
To provide for the connection of shafts of units such as a
motor and generator .
To provide for misalignment of the shafts or to introduce
mechanical flexibility.
To introduce protection against overloads.
• REQUIREMENT OF GOOD SHAFT COUPLING
It should be easy to connect or disconnect the coupling.
It should hold the shaft in perfect alignment
It should have no projecting parts.
• FAILURE OF COUPLING
Improper installation
Poor coupling selection
Operation beyond design capabilities.
• COUPLING CHECK
Understand what caused the failure and to correct before
fixing new coupling. Some external signs :
Abnormal noise, such as screeching, squealing or chattering
Excessive vibration or wobble
Failed seals indicated by lubricant leakage or contamination
• LoopHoles
• Overweight / underweight of use of coupling in case of N.A
• Projecting bolts /studs
BELTS & CHAINS
 BELTS
• A belt is used to mechanically link two or more
rotating shafts.
Belts may be used as a source of motion, to
transmit power efficiently.
Belts are the cheapest equip. for power
transmission between shafts that may not be
axially aligned.
• Pros and cons
Belt drive is simple, inexpensive, and does not
require axially aligned shafts. It helps protect the
machinery from overload and jam, and damps and
isolates noise and vibration
 BELTS
• VEE BELTS • TIMING BELTS

They provide the best (also known as toothed,

combination of traction, notch, cog, or
speed of movement, synchronous belts) are
load of the bearings, a positive transfer belt.
and long service life. When correctly
They are cross-section tensioned, they have no
shape is trapezoidal slippage, run at
(hence the name "V"). constant speed.
 CHAINS
• Chain drive is a way of transmitting mechanical power from one
place to another.
The power is conveyed by a roller chain or transmission chain
passing over a sprocket gear, with the teeth of the gear meshing
with the holes in the links of the chain.
• By varying the diameter of the input and output gears with respect
to each other, the gear ratio can be altered

• Chains versus belts

Roller chain and sprockets is a very efficient method of power
transmission compared to belts, with less frictional loss.
Drive belts can slip..
GEARBOX
 GEARS & TYPES

• A GEAR is a rotating part having cut teeth, or cogs, which mesh with another
toothed part in order to transmit torque. Geared devices can change the speed,
torque, and direction .
Spur gears are simplest type of gear. They consist the teeth projecting radially,.
These gears can be meshed if they are fitted to parallel shafts.
Helical The leading edges of the teeth are not parallel to the axis of rotation, but
are set at an angle. Since the gear is curved, this angling causes the tooth shape to
be a segment of a helix. Helical gears can be meshed in parallel or crossed
orientations.
Spur gears are used for low speed applications and where noise control is not a
problem, the use of helical gears involves high speeds, large power transmission. [
Double helical gears, or herringbone gears, overcome the problem of axial thrust
presented by "single" helical gears, by having two sets of teeth that are set in a V
shape.
 GEARS & TYPES
• A bevel gear is shaped like a right circular cone with most of its tip cut
off. When two bevel gears mesh, their imaginary vertices must occupy
the same point. Their shaft axes also intersect at this point, forming an
arbitrary non-straight angle .
• Spiral bevel gear teeth are curved along the tooth's length and set at
an angle, which are curved along their length, but not angled. Straight
bevel gears are generally used only at speeds below 5 m/s
• Backlash defines it as the maximum distance through which one part
of something can be moved without moving a connected part or a
clearance between mating components, or the amount of lost motion
due to clearance.
Theoretically, the backlash should be zero, but in actual practice some
backlash must be allowed to prevent jamming
GEARBOX LUB.& MAINTANANCE
 What Causes a Short Life for Gear Oil?

Lubricant after too long time / scarce oil quatity

in a high-duty gearbox; it oxidized and
converts into sludge.
 Worm Gears
They can transmit high loads at high-speed ratios. Ratios of 20:1 up to 60:1
• Worm drives are inefficient because the gears experience sliding rather than rolling
contacts, leading to operating temperatures much higher than other gear types.
Spur gears operate at (28°C) while worm gear temperatures (50°C)
• factors affect worm gear efficiency:
Lead angle of the worm
Sliding speed
Lubricant
Surface quality
Installation conditions
• Worm Gear Lube Types

• Extreme Pressure (EP) Gear Oils

EP mineral gear oils are used extensively in worm gears
• Synthetic Worm Gear Oils
They possess superior lubricity properties and have good low and high temperature
properties.
RANGE : 0.05 HP to 90 HP.

REDUCTION RATIO : 5:1, to 70:1. Also higher ratio 100:1

to 4900:1 can be given on Double Reduction.

WORM : The worm is Solid with shaft made of high

grade alloy steel gives hard wear resisting surface duly
case hardened.

WORMWHEEL : made of centrifugally cast Phosphor

Bronze rim shrunk
 How to Inspect a Gearbox
• [a] Good Housekeeping is Essential
Many gearboxes operate in dirty environments during
inspection which may mislead to oil level, ventilation
plug, etc.
• [b] Walkaround Visual Inspection
Before cleaning the gear housing, inspect it for signs
of overheating, corrosion, contamination, oil leaks
and damage.
Measure the tightening torque of structural fasteners
that carry significant loads such as torque arm bolts.
Detecting Overheating
1. Smoke from shafts, seals or breathers
2. Discolored or burnt paint on housings
3. Low oil level in sight glass or on dipstick
4. Dark oil in sight glass or on dipstick
5. Foam in sight glass
6. Water in sight glass or sludge on filter element (may indicate oil cooler failure)
7. Measure gearbox sound and vibration and compare to allowable limits.
8. Measure Temperature of casing by RTD / thermo gauge
• Check Shaft Seals
If there is oil leakages at the shaft seals, probably
ingression of dust and water. If the gearbox has
labyrinth seals, it should have external seals such as V-
rings to prevent contaminant ingression.
• What to Look for
Watch for heavy contact at the edges of the contact
area, Severe misalignment usually causes macropitting.
 P.I.V : Positive power transmission yet infinitely variable stepless speed control.

• The chain is made from steel slats and is free to

move sidewise
When the wheels are close together the chain
operates around a large diameter.
• The principle - varying the driving and driven
diameters - is the principle on which all variable
speed drives
For long life -correct chain tension and oil level .
DESIGN CRITERIA FOR GEARBOX