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Design of a Three Speed Manual Gearbox for Industry Applications

Technical Report · July 2017

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 Report on Three Speed Gearbox Design
Project

General Sir John Kotelawala Defence University

Ratmalana

Name : H.A.J.C.L. Perera

Student Number : ENG/14/027
Subject : Machine Design
Course : B.Sc. in Mechanical Engineering
Acknowledgment

I take this opportunity to express my profound gratitude and deep regards to,

 Mr. R.M.P.S. Bandara - Senior Lecturer, Department of Mechanical Engineering,

General Sir John Kotelawala Defence University

 Mr. Yohan Randana de Silva – Instructor, Department of Mechanical Engineering,

General Sir John Kotelawala Defence University

For their exemplary guidance, monitoring and constant encouragement throughout the course of this
thesis. The blessing, help and guidance given by them time to time shall carry me a long way in the
journey which I am about to embark. I would like to express my gratitude towards my parents & member
for their kind co-operation and encouragement which help me in completion of this project.

I would like to express my special gratitude and thanks to industry persons for giving me such attention
and time. My thanks and appreciations also go to my parents, colleague in developing the project and
people who have willingly helped me out with their abilities and all other not mentioned people who
without which this project would not be possible.

H.A.J.C.L. Perera
Intake 31
Department of Mechanical Engineering
Faculty of Engineering
General Sir John Kotelawala Defence University
Ratmalana- Sri Lanka.

1
List of Contents
Acknowledgment ..................................................................................................................................... 1
List of Figures .......................................................................................................................................... 4
List of Tables ........................................................................................................................................... 5
Chapter 01 ................................................................................................................................................ 6
1.0 Introduction to the Gearbox ............................................................................................................... 6
1.1 Classification of the Gearboxes ......................................................................................................... 6
1.1.1Advantages of the Constant mesh Gearbox ................................................................................. 7
1.1.2 Disadvantages of the Constant mesh Gearbox ............................................................................ 7
1.2 Types of Gears ................................................................................................................................... 7
1.2.1 Spur Gears ................................................................................................................................... 7
1.2.2 Advantages of Spur Gears........................................................................................................... 7
1.2.4 Spur Gear Teeth .......................................................................................................................... 8
1.2.5 Pressure Angle of a Spur Gear .................................................................................................... 8
1.3 Motor Selection .................................................................................................................................. 9
1.3.1 Factors Consider before Selecting an Electric Motor ................................................................. 9
1.3.2 Information of the Electric Motor ............................................................................................... 9
Chapter 02 .............................................................................................................................................. 10
2.0 Spur Gears Arrangement and Calculations ...................................................................................... 10
2.0.1 Spur Gear Arrangement ............................................................................................................ 10
2.0.2 General Information .................................................................................................................. 10
2.0.3 Gear Calculations ...................................................................................................................... 11
2.1 Gear Engagement and Output Speeds .............................................................................................. 12
2.1.1 Fist Gear – 480 rpm .................................................................................................................. 12
2.1.2 Second Gear -- 540 rpm ............................................................................................................ 12
2.1.3 Third Gear – 960 rpm................................................................................................................ 12
2.2 Appearance of the Input and Output Gear Wheels .......................................................................... 13
2.3 Material Selection for Gear Wheels ................................................................................................. 14
2.3.1 Introduction ............................................................................................................................... 14
2.3.2 Properties of Gear Wheel Materials .......................................................................................... 14
2.3.3 Qualities of Medium Carbon Steel............................................................................................ 14
2.4 Gear Wheel Manufacturing .............................................................................................................. 15
2.4.1 Gear Forming ............................................................................................................................ 15
2.4.1.1 Form Milling ...................................................................................................................... 15
2.4.1.2 Broaching ........................................................................................................................... 15
2.4.2 Gear Generating ........................................................................................................................ 15
2.4.3 Finishing Operations ................................................................................................................. 15

2
2.5 Gear Interferences ............................................................................................................................ 16
2.5.1 Methods of Avoiding Interference ............................................................................................ 16
2.6 Heat Treatment................................................................................................................................. 17
2.6.1 Annealing .................................................................................................................................. 17
2.6.2 Hardening .................................................................................................................................. 17
2.6.3 Tempering ................................................................................................................................. 17
2.6.4 Atmosphere Carburizing ........................................................................................................... 17
2.7 Gear Failures Modes ........................................................................................................................ 18
2.7.1 Scoring ...................................................................................................................................... 18
2.8.2 Wear .......................................................................................................................................... 18
2.7.3 Pitting ........................................................................................................................................ 19
2.7.4 Tooth Fracture ........................................................................................................................... 19
Chapter 03 .............................................................................................................................................. 20
3.0 Shaft Calculation .............................................................................................................................. 20
3.0.1 Weight of the Gear Wheels ....................................................................................................... 20
3.0.2 Input Shaft Calculations ............................................................................................................ 20
3.0.2.1 Forces in Vertical Plane of the Shaft.................................................................................. 21
3.0.2.2 Forces in Horizontal Plane of the Shaft ............................................................................. 21
3.0.3 Input Shaft Diameter Calculation ............................................................................................. 22
3.1 Key Calculation ............................................................................................................................... 23
3.2 Cir Clip Selection ............................................................................................................................. 25
3.3 Final View of the Shafts................................................................................................................... 25
3.4 Bearing Calculation.......................................................................................................................... 26
3.4.1 Ball Bearing .............................................................................................................................. 26
3.4.1.1 Ball Bearing Calculation .................................................................................................... 26
3.4.2 Needle Roller Bearing for Output Shaft Gear Wheels .............................................................. 27
4.0 Shifting Mechanism ......................................................................................................................... 28
4.0.1 Components of the Shifting Mechanism ............................................................................... 28
4.1 Lubrication ....................................................................................................................................... 30
4.1.1 Factors which Consider before Selection of Lubrication Oil .................................................... 30
4.1.2 Selection of Lubrication Grade ................................................................................................. 30
4.1.3 Lubrication Types ..................................................................................................................... 31
4.1.4 Functions of the Lubrication System ........................................................................................ 31
4.2 Examining Procedure of the Gearbox .............................................................................................. 31
4.2.1 Procedure .................................................................................................................................. 31
Chapter 05 .............................................................................................................................................. 32
5.0 Conclusion ....................................................................................................................................... 32
References .............................................................................................................................................. 33

3
List of Figures

Figure 1: Appearance of the gearbox ....................................................................................................... 6

Figure 2: Spur Gear Teeth........................................................................................................................ 8
Figure 3: Pressure Angle of a Spur Gear ................................................................................................. 8
Figure 4: Electric Motor........................................................................................................................... 9
Figure 5: Spur Gear Arrangement .......................................................................................................... 10
Figure 6: First Gear Arrangement .......................................................................................................... 12
Figure 7: Second Gear Arrangement ..................................................................................................... 12
Figure 8: Third Gear Arrangement ........................................................................................................ 12
Figure 9: Output Shaft Gear wheel ........................................................................................................ 13
Figure 10: Input Shaft Gear wheel ......................................................................................................... 13
Figure 11: Gear Interferences ................................................................................................................ 16
Figure 12: Scoring Gear Failure............................................................................................................. 18
Figure 13: Wear Pattern of a Gear Wheel .............................................................................................. 18
Figure 14: Pitting Failure ....................................................................................................................... 19
Figure 15: Tooth Facture Failure ........................................................................................................... 19
Figure 16: Forces in Vertical Plane of the Shaft .................................................................................... 21
Figure 17: Forces in Horizontal Plane of the Shaft ................................................................................ 21
Figure 18: Key for Hub and Gears ......................................................................................................... 24
Figure 19: Cir Clip Dimensions ............................................................................................................. 25
Figure 20: View of the Input Shaft ........................................................................................................ 25
Figure 21: View of the Output Shaft ...................................................................................................... 25
Figure 22: Ball Bearing .......................................................................................................................... 26
Figure 23: Needle Roller Bearing .......................................................................................................... 27
Figure 24: Shifting Mechanism.............................................................................................................. 28
Figure 25: First Gear .............................................................................................................................. 29
Figure 26: Second Gear.......................................................................................................................... 29
Figure 27: Third Gear ............................................................................................................................ 29
Figure 28: Lubrication Oil Grade Selection Chart ................................................................................. 30

4
List of Tables

Table 1: Summary of Gear Wheels ........................................................................................................ 11

Table 2: Weight and Force from Gears .................................................................................................. 20
Table 3: Proportions of Standard Parallel Keys ..................................................................................... 23
Table 4: Summary of Keys .................................................................................................................... 24
Table 5: Summary of the Calculated C Values ...................................................................................... 27

5
Chapter 01
1.0 Introduction to the Gearbox

Generally gearboxes are used to increase the torque while reducing the speed of any motor or an engine.
This means that the output shaft of a gearbox rotates at a slower rate than the input shaft, and this
reduction in speed produces a mechanical advantage, increasing torque. And also it increase the
controllability that we have options to shift according to the required condition.
In this project, a three speed Constant mesh gearbox was designed. The design involved shafts, housing,
bearings, mechanical keys, gear shifting mechanism, dog clutches and gear wheels. The design of gear
wheels are based on three speeds (480 rpm, 540 rpm & 960 rpm).

Figure 1: Appearance of the gearbox

1.1 Classification of the Gearboxes

In present days there are many kind of gear arrangements. Basically there are two types based of shifting
mechanism,

 Manual Shifting Gearboxes

 Automatic Shifting Gearboxes
I was designed a constant mesh gearbox which is a Special category of manual gearboxes, Constant
mesh gearbox means all the gears are always in mesh and the engagement between the gears which are
freely rotating on the transmission main shaft and the transmission main shaft is effected by moving
the dog clutches.

6
1.1.1Advantages of the Constant mesh Gearbox

 As the gears are in constant mesh , we can use helical gear which produces less vibration and
noise
 Wear and tear of dog clutch takes place which are easily replaceable
 Wear of dog clutch is less as all the teeth are in mesh

1.1.2 Disadvantages of the Constant mesh Gearbox

 Lower efficiency as compared with sliding mesh type.

 More expensive as additional dog clutch have is being used.
 Working is bit complicated.

1.2 Types of Gears

There are many types of gear wheels such as,

 Spur Gears
 Helical Gears
 Bevel Gears
 Worm and gear set
 Rack and Pinion

In this gearbox designing project, all the gear wheels are spur gears.

1.2.1 Spur Gears

Spur gear are gears with teeth that project outwards from a cylindrical surface. Two spur gears are
used to transmit power between parallel shafts.

1.2.2 Advantages of Spur Gears

 Spur gears have high power transmission efficiency.

 Compact and easy to install.
 Offer constant velocity ratio.
 Highly reliable.
 Can be used to transmit large amount of power (of the order of 50,000 kW).

7
1.2.4 Spur Gear Teeth

Figure 2: Spur Gear Teeth

For standard gears,

 Addendum = A = m (module)
 Dedendum = 1.25 m
Therefore addendum circle diameter, Da = (D + 2A) = (D + 2m)

= mT + 2m; where D = mT

= m(T + 2)

1.2.5 Pressure Angle of a Spur Gear

Figure 3: Pressure Angle of a Spur Gear

8
1.3 Motor Selection
It is an important part when designing a gear box. We have to think about the power producer according
to our requirement. If there isn`t a motor which match with our rpm rate and the required power, we
have to select a motor which near for our requirement and adjust them according to our requirement by
using a pulley system.
A motor which matched with my requirement was found. So a pulley design was not required. So I
recommend to us a rigid coupling to couple the motor with the gearbox directly.

1.3.1 Factors Consider before Selecting an Electric Motor

 Type of power available (Single phase or three phase)

 Ambient Temperature
 Space
 RPM value
 Bearing type
 Required Power
 Base type

1.3.2 Information of the Electric Motor

• Brand name – TAI Series

• Phase – Single phase
• Voltage – 230 V
• Rated RPM – 960
• Output power – 10 HP (7.5 kW)
• Service factor – 1.1
• Type of the service – Medium type (10-16 hrs. /day)

Figure 4: Electric Motor

9
Chapter 02
2.0 Spur Gears Arrangement and Calculations
2.0.1 Spur Gear Arrangement

D3 D1 D

D4 D2 D

Figure 5: Spur Gear Arrangement

2.0.2 General Information

Diameter of a gear wheel (D) = m T (where T = No. of teeth)

Center distance of the two shafts = m ( T3 + T4 ) / 2

All the gear wheels on input shaft are fixed with keys and all the gear wheels on output shaft are on
needle bearings. They are always meshing with the input shaft gear wheels. Once the sliding dog clutch
is engaged with the dog teeth on output shaft gear wheel, the power can be transmitted through the output
shaft.

10
2.0.3 Gear Calculations

First Gear
N3 = 960, N4 = 480, T3 was taken as 25, m = 2, T4 =?
N3 T4
= , T3 was taken as 25
N4 T3
960∕480 = T4 ∕25
Then,
T4 = 50

𝑚 (𝑇3+𝑇4) Centre distance of the shafts

= 2 ( 25 + 50 ) / 2
= 75 mm
By using above equations we can also get the T1, T2 and T. That calculated values are mentioned in
below table

Table 1: Summary of Gear Wheels

Also the face width can be calculated by,

B = 8(m) here m means module

 For gear wheels which have m=2 face width is 16mm

 For gear wheels which have m=3 face width is 24mm

11
2.1 Gear Engagement and Output Speeds
2.1.1 Fist Gear – 480 rpm

Figure 6: First Gear Arrangement

2.1.2 Second Gear -- 540 rpm

Figure 7: Second Gear Arrangement

2.1.3 Third Gear – 960 rpm

This arrangement achieves the highest speed (960 rpm) of the gear box obtaining lowest torque. Both
the gear wheels have same number of teeth (25) and same speeds (960 rpm).

Figure 8: Third Gear Arrangement

12
2.2 Appearance of the Input and Output Gear Wheels

Figure 9: Output Shaft Gear wheel

Figure 10: Input Shaft Gear wheel

According to the above figures, left side gear wheel is fixed to the input shaft and right side gear wheel
is fixed to the output shaft. Dog teeth can be seen on the output shaft gear wheel.

13
2.3 Material Selection for Gear Wheels

2.3.1 Introduction

When consider about the selection of material for gear wheel, there are mainly three factors that are most
important. They are strength, durability, and cost, which includes both the cost of the material and the
cost of manufacturing. While the importance of these factors may vary from one application to another,
the key to material selection is finding the right combination of physical properties that satisfy the
requirements of the project at the lowest cost.

2.3.2 Properties of Gear Wheel Materials

 High tensile strength to prevent failure against static loads.

 High endurance strength to withstand dynamic loads.
 Low coefficient of friction.
 Good manufacturability.

2.3.3 Qualities of Medium Carbon Steel

 Approximately 0.3–0.6% carbon content. Balances ductility and strength and has good wear
resistance
 Good toughness and ductility.
 Relatively good strength, thus it can transmit power/torque more efficiently and has a longer
life.
 Can be hardened by quenching.

14
2.4 Gear Wheel Manufacturing

Gears can be manufactured by processes such as casting, forging, extrusion, powder metallurgy,
blanking etc. But as a rule, machining is applied to achieve the final dimensions, shape and surface finish
in the gear. The initial operations that produce a semi finishing part ready for gear machining as referred
to as blanking operations; the starting product in gear machining is called a gear blank.
Principal methods of gear manufacturing include,

 Gear forming
 Gear generation
 Finishing operations

2.4.1 Gear Forming

In gear form cutting, the cutting edge of the cutting tool has a shape identical with the shape of the space
between the gear teeth. Below two machining operations can be employed to form cut gear teeth.

 Form milling
 Broaching

2.4.1.1 Form Milling

In form milling, the cutter called a form cutter travels axially along the length of the gear tooth at the
appropriate depth to produce the gear tooth. After each tooth is cut, the cutter is withdrawn, the gear
blank is rotated (indexed), and the cutter proceeds to cut another tooth. The process continues until all
teeth are cut.

2.4.1.2 Broaching

Broaching can also be used to produce gear teeth and is particularly applicable to internal teeth. The
process is rapid and produces fine surface finish with high dimensional accuracy. However, because
broaches are expensive-and a separate broach is required for each size of gear-this method is suitable
mainly for high-quantity production.

2.4.2 Gear Generating

In gear generating, the tooth flanks are obtained (generated) as an outline of the subsequent positions of
the cutter, which resembles in shape the mating gear in the gear pair. In gear generating, two machining
processes are employed, shaping and milling. There are several modifications of these processes for
different cutting tool used.

2.4.3 Finishing Operations

As produced by any of the process described, the surface finish and dimensional accuracy may not be
accurate enough for certain applications. Several finishing operations are available, including the
conventional process of shaving, and a number of abrasive operations including; grinding, honing, and
lapping.
15
2.5 Gear Interferences

It is a phenomenon in which the non-involute portion in gear teeth comes into contact with the meshing
teeth. This results in removal of material near the root region, loss of motion, power etc.

Figure 11: Gear Interferences

2.5.1 Methods of Avoiding Interference

 Under Cutting - Undercutting below the root diameter avoids interference and clashing when
there is an error in the center distance between gear shafts eccentricity of mounting. This weaken
the strength of the tooth alternately one could increase the center distance which would increase
noise, reduce perfect rolling between gears.

 Change of Pressure angle - The same cutter between pairs of gear and grind the cutter and
correct profile as they wear out. Increasing the pressure angle produces reduction in the height
of Gear teeth and is equivalent to stubbing.

 Tooth thinning - This method also can be used to avoid gear interferences. But can`t be used in
earlier application because its strength was decreased by tooth thinning

16
2.6 Heat Treatment

Heat treatment is a critical and complex element in the manufacturing of gears that greatly impacts how
each will perform in transmitting power or carrying motion to other components in an assembly. It
optimize the performance and extend the life of gears in service by altering their chemical, metallurgical,
and physical properties such as surface hardness, core hardness, case depth, ductility, strength, wear
resistance and compressive stress profiles can vary greatly depending on the type of heat treatment
applied.

 Annealing
 Hardening
 Tempering
 Atmosphere Carburizing

2.6.1 Annealing

Annealing is one of the most important heat treatment operation applied to steel. It is the process of
heating the steel in a furnace to a point not exceeding 50° above its upper critical point and maintaining
the steel at that temperature for a considerable time (30-60 minutes) to convert the whole steel to
austenite. Then the Steel is allowed to cool down slowly through a medium of hot sand, hot ashes or hot
lime dust. The rate of cooling is to be maintained at a constant temperature rate such as 150-200ºC per
hour.

2.6.2 Hardening

In hardening process, the steel is firstly heated up to a point exceeding 50ºC above the upper critical
point for hypo-eutectoid steels and 30-50ºC above for hyper-eutectoid steel. Then the steel is soaked at
this temperature for a considerable time to ensure that all the pearlite and cementite have changed into
austenite. After that the steel is cooled rapidly to keep the austenite to remain as such at room
temperature. This process consists of two operations called heating and quenching. If these two
operations are properly carried out, then the required structure is obtained. (In quenching the heated steel
is suddenly cool by using an oil, water or other cooled media.)

2.6.3 Tempering

Martensite is stable only up to 200ºC. If a piece of steel, which has been hardened, is subsequently heated
to a temperature above 200ºC, the decomposition of martensite will start taking place. This
decomposition is in the order of troostite first and then sorbite. Martensite decomposes into troostite,
which is a finely dispersed mixture of cementite and ferrite, in the temperature ranges of 200-300ºC.
Tempering at temperature between 500-600ºC will lead to the formation of the globular structure of
sorbite. The object of tempering is to remove excessive brittleness and induce toughness.

2.6.4 Atmosphere Carburizing

Carburizing is the most widely used form of surface hardening, it is the process of diffusing carbon into
the surface of low carbon steel at elevated temperatures and this results in a high carbon case forming
just inside the surface of a low carbon component. During quenching from austenitizing temperatures
the austenite will transform into martensite, and the higher carbon case will have a high hardness while
the lower carbon core material will have a lower hardness. The ultimate goal of this process is to produce
a hard, strong, wear resistant outer surface while retaining a softer, ductile tough core.
17
2.7 Gear Failures Modes

Gear failure can occur in various modes. If care is taken during the design stage it to prevent each of
these failure a sound gear design can be evolved.

 Scoring
 Wear
 Pitting
 Tooth fracture

Some of the reasons for gear failures are

 Metal-to-metal contact due to lack of oil film.

 Ingress of abrasive particles in the oil.
 Chemical wear due to the composition of oil and its additives.
 Work under overloads

2.7.1 Scoring

Figure 12: Scoring Gear Failure

Scoring is due to combination of two distinct activities. First, lubrication failure in the contact region
and second, establishment of metal to metal contact. Later on, welding and tearing action resulting from
metallic contact removes the metal rapidly and continuously so far the load, speed and oil temperature
remain at the same level.

2.8.2 Wear

Figure 13: Wear Pattern of a Gear Wheel

As per gear engineer’s point of view, the wear is a kind of tooth damage where in layers of metal are
removed more or less uniformly from the surface. It is nothing but progressive removal of metal from
the surface. Consequently tooth thins down and gets weakened. Three most common causes of gear tooth
wear are;
18
2.7.3 Pitting

Figure 14: Pitting Failure

Pitting is a surface fatigue failure of the gear tooth. It occurs due to repeated loading of tooth surface and
the contact stress exceeding the surface fatigue strength of the material. Material in the fatigue region
gets removed and a pit is formed. The pit itself will cause stress concentration and soon the pitting
spreads to adjacent region till the whole surface is covered. Subsequently, higher impact load resulting
from pitting may cause fracture of already weakened tooth. However, the failure process takes place
over millions of cycles of running. There are two types of pitting, initial and progressive

2.7.4 Tooth Fracture

Figure 15: Tooth Facture Failure

Tooth fracture is the most dangerous kind of gear failure and leads to disablement of the drive and
frequently to damage of other components (shafts, bearings, etc.) by pieces of the broken teeth. Tooth
breakage may be the result of high overloads of either impact or static in nature, repeated overloads
causing low-cycle fatigue, or multiple repeated loads leading to high cycle fatigue of the material.

19
Chapter 03
3.0 Shaft Calculation

In order to determine the diameter of the Input and Output shafts, all the stresses and forces on the shaft
should be determined. Therefore some pre calculations to be done before the shaft diameters
calculations.

3.0.1 Weight of the Gear Wheels

Weight = Density × Volume
Density of the Gear Wheel and Dog Clutch material = 7.83 𝑔∕𝑐𝑚3
Length of the Dog Clutch = 25 mm
Ex: - Finding the weight of the gear wheel D

W = 7.83g/cm3 × 3.14 × (7.5cm)2 × (2.4cm) /4

= 830 g
= 0.83 kg
Applying same method, weight of the other gear wheels can be found.
Table 2: Weight and Force from Gears

Gear Wheel D D1 D2 D3 D4

Weight (kg) 0.83 0.43 1.36 0.246 0.98

Force due to
Weight 8.14 4.22 13.34 2.41 9.64
(N)

3.0.2 Input Shaft Calculations

Torque transmitted by the shaft, T = P60/2πN = (7.5 × 1000 × 60) / (2 × π × 960)

= 74.6 Nm
Tangential force on gear = Ft = T/R = 2T/D = (2 × 74.6) / 0.05 = 2984 N
Pressure angle (φ) = 200 and normal load acting on the tooth of gear wheel = F

F Cos (20) = Ft
F = 2984/ Cos(20) = 3175.5 N
Vertical load acting on the shaft = Ft = 2984 N

Horizontal load acting on the shaft = F sin 20 = 3175.5 × Sin (20) = 1086 N

20
3.0.2.1 Forces in Vertical Plane of the Shaft

0.36m 0.69m 0.69m 0.02m

1 2
re

R1 (2984+2.41) N 4.22 N 8.14 N R2

Figure 16: Forces in Vertical Plane of the Shaft

Each forces and reactions positions are labeled in the diagram. 1, 2 are the bearing positions

Taking moments around 1, R2 = 317.46 N

Considering vertical load equilibrium, R1 = 2435 N

Considering the shear force distribution diagrams and bending moment diagrams, maximum bending
moment on the input shaft is occurred at the bearing (1) and its value is 87.66 N m.

3.0.2.2 Forces in Horizontal Plane of the Shaft

1086N

1 0.036 0.158m 2
m

R1 R2

Figure 17: Forces in Horizontal Plane of the Shaft

Taking moment around 1, R2 = 247.44 N

Considering force equilibrium R1 = 838.56 N

Considering the shear force distribution diagrams and bending moment diagrams related to horizontal
plane, maximum bending moment on the input shaft is 30.18 N m.

Therefore the resultant bending moment on the input shaft = 92.70 Nm

21
3.0.3 Input Shaft Diameter Calculation

For the calculations of input shaft diameter, it is taken that the shear stress of the mild steel shaft is 56
N/mm2 and diameter is‘d’.

 Km = Combined shock and fatigue factor for bending = 1.5

 Kt = Combined shock and fatigue factor for torsion = 1.5

In order to design such shafts like line shafts and counter shafts, the combined shock and fatigue factors
must be taken into account for the computed twisting moment (T) and bending moment (M). Thus for
a shaft subjected to combined bending and torsion, the equivalent twisting moment;

Te = √(Km × M)2 + (Kt × T)2

And equivalent bending moment;

1
Me = 2 [Km × M + √(Km × M)2 + (Kt × T)2]

Therefore; here km = kt = 1.5, M = 92.70 N m, T = 74.6 N m

2
Te = √(1.5 × 92.7)² + (1.5 × 74.6 )²
= 178.48 N m
= 178480 N mm

Also know that;

π
T= × τ × d3
16

d = 25.31 mm for the easiness in fabricating processes the diameter of the input shaft was taken as
30mm.
Also we can calculate the output shaft diameter by using above method. The calculated diameter value
for output shaft is 28.83mm, this also taken as 30 mm for easy fabrication.

22
3.1 Key Calculation

A key is a piece of mild steel inserted between the shaft and hub to connect these together in order to
prevent relative motion between them. It is always inserted parallel to the axis of the shaft. Keys are
used as temporary fastenings and are subjected to considerable crushing and shearing stresses. A keyway
is a slot or recess in a shaft and hub of the pulley to accommodate a key.
Table 3: Proportions of Standard Parallel Keys

Width and thickness of the key can be taken from the chart and the length of it should be calculated. In
order to calculate the length of the key, following equations should be taken into account.

π
T= × τ × d3
16
d d
T=F× =l×w× τ×
2 2
d t d
T = F × = l × × σc ×
2 2 2

• The torque (T) = π × 56 × (30)3 / (16) = 178480 N mm

The shear stress of the key material is 150 N/mm2

178480 N mm = l × 10 mm × 150 N/mm2 × 15 mm

Length of the key = 7.93mm---------------------------------------------------------- 1

The crushing stress of the key material is 250 N/mm2

178480 N mm = l × 4 mm × 250 N/mm2 × 15 mm
Length of the key = 11.89 mm----------------------------------------------------- 2
23
From 1 & 2 answers, length must be equal or more than 11.89 mm
Therefore the key lengths were taken equal to the gear wheel width (16mm and 24mm) because of both
input and output shafts are equal diameter(30mm) above calculated key dimensions were used in both
shafts.
Hub of the dog clutch unit is fixed to the 30 mm diameter output shaft with keys. The width and thickness
of the key is 10 mm and 8 mm respectively. The key material is same as previous key material which is
used for gear wheels.
π
• The torque (T) = 16 × 56 × 303 = 296880.5 Nmm

The shear stress of the key material is 150 N/mm2

296880.50 N mm = l × 10 mm × 150 N/mm2 × 15 mm

Length of the key = 13.19 mm ------------------------------------------------------- 3

The crushing stress of the key material is 250 N/mm2

296880.50 N mm = l × 4 mm × 250 N/mm2 × 30 mm
Length of the key = 19.79 mm -------------------------------------------------------- 4

Therefore the key for hub is 25 mm which is higher than the maximum value of the calculated length
for key.

Figure 18: Key for Hub and Gears

Table 4: Summary of Keys

Key is used for Dimensions (w × t × l)

10 mm × 8 mm × (24 mm or 16mm)
Gear wheels

10 mm × 8 mm × 25 mm
Hub

24
3.2 Cir Clip Selection
External circlips are retaining rings for holding structural parts (e.g. rolling bearings) on shafts. Circlips
are fitted with spring retention in grooves and are suitable for the transmission of axial forces. Material
of the circlip is carbon spring steel.

Figure 19: Cir Clip Dimensions

Both shafts are 30mm of diameter, so the selected Cir clip was used for both shafts
Groove width (W) = 2.55 mm
Groove diameter (G) = 28.2 mm

3.3 Final View of the Shafts

Figure 20: View of the Input Shaft

Figure 21: View of the Output Shaft

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3.4 Bearing Calculation
3.4.1 Ball Bearing

Bearing is a device that is used to enable rotational or linear movement, while reducing friction and
handling stress. Resembling wheels, bearings literally enable devices to roll, which reduces the friction
between the surface of the bearing and the surface it's rolling over. Input shaft and the output shaft is
held by ball bearings. Each shaft is consisted of two ball bearings which are tightly fitted to the shaft and
to the housing.

3.4.1.1 Ball Bearing Calculation

For Input shaft

hrs.per day×60×days per year×years×rpm

L10= Million revolutions
1000000
For this application,
Hours/day =10
Days = 200
Years = 2
Rpm = 960

L10 value can be calculated and it is 324 million revolutions. C = P

(L10)1/3

For input shaft P = 2435 N (Largest reaction value from R1 and R2)
Therefore calculated C value is 14927.70
From the standard ball bearing selection table, under 30 mm diameter category C value is 15000.
Therefore bearing number 6206.
Following the same procedure, output shaft bearing was determined. Its bearing number is 6206

Figure 22: Ball Bearing

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3.4.2 Needle Roller Bearing for Output Shaft Gear Wheels

Since the Constant Mesh technology is used, the output shaft gear wheels must be able to rotate freely
on bearings. Type of bearing is needle roller bearings.
Resultant force due to gear wheel A is calculated as follows.

Torque transmitted, T = P×60/2πN = (7.5×1000×60) / (2×π×480) = 149.2 N m.

Tangential force = Ft = 2T/R = (2×149.2) / 0.1 = 2984 N

Normal load (Resultant force) = F = Ft / Cos (20) = 2984/ cos (20) = 3175.5 N
Calculated C value for bearing = 12621.45
Likewise, C value for other two gear wheels can be calculated.

Table 5: Summary of the Calculated C Values

Gear Wheel Calculated C Value

D 9559.5

D2 12484.9

D4 12621.45

By considering the table vales for C, and thickness of the needle roller bearing 25200 was chosen
as the C value from the table.

Figure 23: Needle Roller Bearing

27
Chapter 04

4.0 Shifting Mechanism

In order to select the required gear, gear selecting (changing) mechanism is come up with this
gearbox.

4.0.1 Components of the Shifting Mechanism

 Gear lever
 Gear selecting rods
 Forkes
 Dog clutch
 Gear wheels

Figure 24: Shifting Mechanism

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 Figure 25: First Gear

Figure 26: Second Gear

Figure 27: Third Gear

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4.1 Lubrication

Lubrication is the action of applying a substance such as oil to a component where metal to metal contact
occurs and minimize the friction and allow smooth movement. If the oil levels fall too low, the gearbox
will likely fail. Gearbox failure can lead to expensive repairs that could be prevented. Besides added
costs due to replacement or repair, costs associated with a loss of production could be significant. These
issues are why it is important to understand the consequences of having low lubricant levels.
Understanding the functions of industrial gearbox lubricating oil can help you choose the right oil for
your equipment and help prevent gearbox failures.

4.1.1 Factors which Consider before Selection of Lubrication Oil

 Speed
 Materials used
 Temperature
 Load
 Type of motion
 Cost
 Lifetime

4.1.2 Selection of Lubrication Grade

The average operating temperature of the gearbox is about 500 C.

Figure 28: Lubrication Oil Grade Selection Chart

Since the average operating temperature is 500 C SAE 20W-60 is selected as lubrication oil grade.

30
4.1.3 Lubrication Types

Generally there are two types of lubrication methods,

 Splash Lubrication
 Force Lubrication (By using an external force ex: Gear pump)

In my design I used the splash lubrication method which splashes oil to all the parts inside the
gearbox by the force created from the rotation of the gear wheels.

4.1.4 Functions of the Lubrication System

 It reduces friction and prevents metal-to-metal contact

 It carries away a considerable amount of heat (cooling)
 protects working surface against corrosion
 removes gritty and carbonaceous deposits of the working surface
 cushions the parts against impact and vibration
 reduces operation noise

4.2 Examining Procedure of the Gearbox

Mainly following three things are checked.

 Gear teeth condition

 Gear teeth wear pattern
 Lubrication system
 Gear Shifting

4.2.1 Procedure

 Firstly clean the area around inspection cover.

 Then Remove the nuts from inspection covers and inspect the gears with rotating the shafts.
 Checking the gear tooth wear patterns and take actions if necessary.
 Checking lubricating system.
 After doing inspections or repairs, clean the inside of the gearbox (if necessary).
 Fix the removed parts carefully.
 Do a test drive before stating the operations.

31
Chapter 05
5.0 Conclusion

This is a three speed manual transmission constant mesh type gearbox which can be used in industrial
applications such as rubber or chemical mixing processes. It is designed for a higher power applications
near 7.5kw.

 Three speed (480, 540, 960 rpm) gear box

 7.5 kW of power

When design this gearbox it required the knowledge of materials machine design and Solid works
drawing skills. I have learnt the steps and processes in designing the gearbox consists of spur gears,
bearings, shafts, keys calculations as well as housing. Other than that, I also learnt about the methods and
ways to apply the formulas correctly while maintaining the specifications required in the designing
process by apply what I have learnt in machine design subject.

In my gearbox design mild steel was selected for the material of the gear wheels and shafts. Once the
gear dimensions were finalized, the design of the shafts were initiated. The shafts had to be long enough
to allow enough space for the width of the gear, dog clutch, circlips and bearing. The shafts also had to
have a large enough diameter to prevent the shafts from bending as a result of the resultant force
generated by the gears. So that I took a bit higher dimensions for the shaft diameter than the calculated
value.

After designed the gear wheels and shafts, the housing was the final component to be designed for this
gear box system. The housing needed to provide support for bearing holders, space for an input and
output shaft, and it needed enough space to accommodate gear wheels and the shifting mechanism. Also
consider about the inspection window, deep stick and the sump. They should be easy to access for the
operator. So I designed the housing to meet above conditions. Also the sump nut is designed with a
magnetic part to attach the metal particles which were a result of metal to metal contact of gear wheels
and mixed with oil.

Although designing a gearbox is a very challenging task. A few challenges were faced. Firstly I designed
it with a pulley system and there occurred some unavoidable problems and I again design it without the
pulley system. Finding a electric motor which produce the required power and speed also another
difficult task. After all, I manage to overcome the problems by get ideas from my friends, browsing
through internet, guidance and support from the lecturers. So this is a great experience for me as a
mechanical engineering undergraduate and it helps me to develop my designing skills and the
knowledge in machine design.

32
 References

(n.d.). Retrieved 2017, from http://www.azom.com/article.aspx?ArticleID=6742 (n.d.). In

Machine Element and Designs.
(n.d.). Retrieved 5 21, 2017, from
(n.d.). Retrieved 2017, from http://www.brighthubengineering.com/marine-enginesmachinery/53664-
when-should-lube-oil-be-changed/
(n.d.). Retrieved 2017, from http://www.amarillogearservice.com/importance-industrial-gearbox-
lubricating-oil/
(n.d.). Retrieved 2017, from https://www.quora.com/What-are-advantages-and-disadvantages-of-
constant-mesh-gearbox

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