Machine Design II

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Module 2 - GEARS
Lecture 17 DESIGN OF GEARBOX
Contents
17.1 Commercial gearboxes
17.2 Gearbox design.
171 COMMERCIAL GEARBOXES
Various commercial gearbox designs are depicted in Fig. 17.1 to 17.10. hese include
single to multistage ranging !rom spur" helical" be#el to $orm gears.
F!"171 Co##erc!$l Ge$r%o& Des!"n
F!" 172 '(o st$"e )el!c$l "e$r%o&
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Machine Design II
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F!"17* A s!n"le st$"e %e+el "e$r%o&
F!"17, -or# "e$r%o&
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Machine Design II
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F!"17. -or# "e$r%o&/ sect!on$l 0ront $nd s!de +!e(s
F!"171 -or# "e$r%o&/ (!t)out cool!n" 0!ns/ sect!on$l 0ront $nd s!de +!e(s
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Machine Design II
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F!"177 2el!c$l "e$r lu%r!c$t!on (!t) !dler "e$r F!"173 S4ur "e$r lu%r!c$t!on
(!t) stre$# %5 no66les
F!"177 A dou%le reduct!on s4ur "e$r %o&
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Machine Design II
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F!"1718 Be+el "e$r S4ur "e$r tr$ns#!ss!on
172 2ELICAL GEARBOX DESIGN - 9ROBLEM 1
In a turbine dri#e %00 &' po$er is transmitted using a pair o! double helical gear. he
pinion speed is 2()0 rpm and that o! the gear is about *1+.) rpm. here are no space
constraints on the gear dri#e. ,electing suitable materials" design the pinion and the
gear to last !or 10
*
c-cles. Design the gearbox completel-.
D$t$: ' . %00&'/ n
1
. 2()0rpm/ n
2
0 *1+.) rpm/ Desired 1i!e 10
*
c-cles.
Solut!on:
1. 2ngular speed o! the input sha!t
; =
2<n
1
=
2< & 27.8
= *8377 r$d = s
1
18 18
'
1888-
=

1888&*88
=
7711 N#
2. or3ue4
1
=
; *8377
%. he details o! the gear design carried out are gi#en in able 1 and 2.
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he !inal speci!ications o! the pinion and gear are4
20
o
pressure angle in#olute teeth $ith helix angle o! %)
o
" h
a
.1m
n
" h
!
.1.2)m
n
.
i. 5
2
6 5
1
.10)62(. %.+2
'$%le 171 Ge$r d!#ens!ons
7lement 5 m
n
mm
d mm d
a
mm d
b
mm d
r
mm m
t
mm
8inion 2( ) 177.01 1*7.01 1+1.7+ 1+9.)1 +.109
Gear 10) ) +90.(2 +)0.(2 )*).+( +2*.92 +.109
'$%le 172$ Ge$r s4ec!0!c$t!ons
7lement :
n
;
t
< mm p
t
mm p
a
mm
8inion 20
o
2%.(+
o
70 1(.1+) 27.%7
Gear 20
o
2%.(+
o
70 1(.1+) 27.%7
'$%le 172% Ge$r s4ec!0!c$t!ons
7lement C=
t
C=
a
C= F, s
b
F, s
>
8inion 1.%099 1.27*7 2.)*% 1.(( 1.7%
Gear 1.%099 1.27*7 2.)*% 1.*( 1.)%
F!"1711 >$? 9!n!on F!"1711 >%? Ge$r
2ll dimensions are in mm and not to scale
F!"1712 A co##erc!$l dou%le )el!c$l "e$r%o&
r
% t
F!"171* Ge$r %o& outer
d!#ens!ons >tent$t!+e?
F!"171, 9!n!on s)$0t l$5out d!$"r$#
2ll dimensions are in mm
, ,ha!t design is based on the 2,M7 e3uation4
angential load on the sha!t4 F
t
. 6r . (71.+60.0**.) . 11&?
F
r
.F
t
tan @ .11tan2%.(+
o
. 9.*(&?
F . AF
t
2
B F
2
C
0.)
. A11
2
B 9.*(
2
C
0.)
.1).92&?
<ending moment at C
M . Fl 69 .1).92x0.1)69.0.)* &?m
F!"171. S)$0t Lo$d!n"
<- 2,M7 code e3uation !or sha!t design $e ha#e"
d =
11
>1 @?AB
>C M?
2
+ >C '?
2
# t
1
& . 0.2 i.e" 20D reduction in strength due to &e-$a- is assumed. From able 17.%" !or
rotating sha!t $ith minor shoc& loads" E
b
. 1.) and E
t
. 1.0.
a&ing C9) steel !or the sha!t" F
-p
. %+0 M8a
G
-p
. F
-p
62 . %+062 . 1*0 M8a and ta&ing !actor o! sa!et- o! HGI . G
-p
62 . 1*062 .(0 M8a
'$%le17 * Co#%!ned s)oc@ $nd 0$t!"ue 0$ctors 0or ASME code s)$0t des!"n
eDu$t!on
-pe o! loading E
b
E
t
,tationar- sha!t
Graduall- applied load 1.0 1.0
,uddenl- applied load 1.)J2.0 1.)J2.0
=otating sha!t
Graduall- applied load 1.) 1.0
,uddenl- applied load
'ith minor shoc&s 1.)J2.0 1.0J1.)
'ith hea#- shoc&s 2.0J%.0 1.)J%.0
d =
11
>1 @?AB
>C M?
2
+ >C '?
2
d =
11 & 18
>1.&8.3?
2
+ >1&87711?
2
= ,1 ##
>1 82?&78
a&e d . )0 mm. Chec& !or de!lection at the pinion centre.
Fl
*
*
1.,28 & 1.8
De!lection at C4
= = = 8817 ##
,3EI &.8
,
,3 X21&18
.
> ?
1,
,ince K L 0.01m . 0.01x) . 0.0) mm" the design is ME.
Chec& !or slope at the bearing at 2.
2 2
,lope4
=
FL
11EI
=
1.,28&1.8
&.8
,
11&21&18
.
&> ?
1,
= 8888*, r$d
N L 0.000* rad. >ence the design is ME.
.. Chec& !or the pinion siOe. he minimum pitch diameter o! the pinion should be
d
1min
P 2 x bore B 0.2) m
$here d is the bore diameter and m is the module expressed in mm.
D
1min
P 2bore B0.1m. 2x)0 B 0.1x) . 100.) mm
,ince d
1
. 177.01 mm Q D
1min
. he design is satis!actor-. 8inion dra$ing is sho$n in
Fig.17.1+ $ith !ull dimensions.
1 he outside diameter o! the hubs in larger gears should be 1.* times the bore !or
steel. he hub length should be at least 1.2) times the bore and ne#er less than the
$idth o! the gear.
Gear sha!t diameter . d AiC
16%
. )0 A%.+2C
16%
. 77 mm.
Gear sha!t diameter o! *0 mm is ta&en.
he hub diameter4 d
>
. 1.* x *0 . 199 mm" 1)0 mm is ta&en.
>ub length is ta&en as 1 .1.2)d .1.2) x*0 0100 mm
Mther dimensions o! the gear are gi#en in Fig. 17.17.
In #ie$ o! the dimensions o! the pinion and the gear" the dimensions o! the sha!t la-out
is re#ised as sho$n in Fig.17.1* 'hen the calculations are redone" there is no change
in sha!t diameters. he same diameters are adopted !or !urther computations.
F!"1711 9!n!on %l$n@ dr$(!n" F!"1717 Ge$r %l$n@ dr$(!n"
'$%le 17, D!#ens!ons o0 4!n!on $nd "e$r %l$n@
8arameters 8inion Gear
d
d
1
<
C
D
e
m
D
o
n
D
1
d
2
1
'
Ee-$a-
depth
)0 mm
1.*d 0 (0 mm
70 mm
0.%< 0 22 mm
1*7.01 mm
) mm
0 D
e
R 10m . 1%7 mm
0.) m . 2.) mm
AD
o
B d
1
C 6 2 . 119 mm
0AD
o
R d
1
C 6 ) . 10 mm
1.2) d . 70 mm
0.2) d . 12.) mm
0.12)d 0 + mm
*0 mm
1.*d 0 1)0 mm
70 mm
0.% < 0 22 mm
+)0.(2 mm
) mm
0 D
e
R 10m . +00 mm
0.) m . 2.) mm
AD
o
B d
1
C 6 2 . %7) mm
0AD
o
R d
1
C 6 ) . (0 mm
1.2)d 0 100 mm
0.2)d . 20 mm
0.12)d 0 10 mm
F!" 1713 9!n!on s)$0t l$5out d!$"r$#
7 <earings selection is based on (0D reliabilit- !or the !ollo$ing li!e4
* hrs. Mperation per da- li!e. 20"000J %0"000 hrs.
Consider the bearings at 2 S < $ith 1i!e . %0"000 hrs"
8 . 1)920 6 2 . 7710 ?"
!
n
. 0.229 !or n . 2()0 rpm !rom F2G catalog.
!
1
. %.(1 !or %0000 hrs li!e assuming 1+ hrs6da- $or&ing !rom F2G catalog.
C . A!
1
6 !
n
C 8 . A%.(160.229Cx7710 .1%9)*1? .1%9.+&?
Gi#ing 2.) mm abutment !or the bearings" sha!t diameter o! the bearing should be 9)
mm.
=oller bearing ?T 2%0( satis!ies this re3uirement
C . 1%7 &?" C
o
. 1)% &?" d
o
.100 mm" d
i
. 9)mm" b . %+mm.
For the gear sha!t o! diameter *0mm" gi#ing abutment o! 2.) mm" bearing bore diameter
should be 7)mm.
8 . 7710 ?"
!
n
. 0.%9) !or sha!t speed o! *1) rpm.
!
1
. %.(1 !or 1i!e o! %0"000 hrs.
C. A!
1
6 !
n
C x 8 . A%.(1 6 0.%9)Cx 7710 . *7"%*0 . *7.%* &?
Deep groo#e ball bearing +%1) $ith C.119&?" C
o
.+7&?/ d
o
. 1+0 mm/ d
i
. 7)mm/
b.%7mm.
3 Gearbox dimensions are !ixed based on thumb rule gi#en in able 17.).
'$%le 17. -$ll t)!c@ness EsF !n ## o0 t)e "e$r%o&es
Material ?onJcase hardened
gears
Case hardened gears
CI castings 0.0071 B + mm 0.010 1 B + mm
,teel castings 0.00)1 B 9 mm 0.0071 B 9 mm
'elded construction 0.0091 B 9 mm 0.00)1 B 9 mm
'here 1 is the largest dimension o! the housing in mm.
s . 0.00)1 B 9 mm .0.00)x (00 B 9 0 10 mm
op co#er thic&ness4 ,
c
. 0.*s .* mm.
Flange thic&ness4 s! . 2s . 2x10 . 20 mm
Flange co#er bolt diameter4 d
cb
. 1.)s 01+ mm M1+ bolts.
<olt spacing4 +d . +x1+ 0 100 mm
Foundation bolt diameter4 d
!b
. A2C
16%
P 12 mm
d
!b
. A2x%.+2x(71.+C
16%
. 1(.2" a&e M20 bolts.
he thic&ness o! the !oundation !lange should be4
,
!!
P 1.) d
!b
. 1.)x20 . %0 mm
he $idth o! the !lange at the base4 $
b
. 2.)d . 2.) x 20 . )0 mm
he $idth o! the !langes at the t$o hal#es o! the housing should be4
$
!
. 2.)d . 2.) x 1+ . 90
'ith $elding bead o! )mm" $! . 9) mm is ta&en.
Mutside dimension o! the bearing housing 1.2J1.) times outside diameter o! the bearing.
<earing housing diameters are4 1.)x100 . 1)0mm and4 1.%x1+0 . 210 mm ta&ing +
?os. M10 bolts !or the bearing co#ers.
he #ie$s o! the bottom and top hal! o! the gearbox are sho$n in Fig. 17.1( and
Fig.17.20.
F!"1717 G!e( o0 %otto# )$l0 o0 t)e "e$r%o&
F!"1728 G!e( o0 to4 co+er o0 t)e "e$r%o&
RECOMMENDED OIL FOR GARIOHS SLIDING S9EEDS
'$%le 171 Reco##ended o!l +!scos!t5 G.8 AcSt $t .8
o
CB 0or d!00erent sl!d!n"
s4eeds
#Am6sC 0.2) 0.9 0.+% 1.0 1.+ 2.)
V
)0
min 17) 19) 120 100 *% +(
V
)0
max %)0 2(0 290 200 1++ 1%*
#Am6sC 9.0 +.% 10 1+ 2) 90 +%
V
)0
min )7 97 %( %2 27 22 1*
V
)0
max 119 (9 7* +9 )9 99 %+
he gears are operating at a sliding speed o! # . Ur . %0*.77x0.0**) . 27.%% m6s.
From the able 17.+" the recommended oil #iscosit- at )0
o
C !or this operation is V
)0
bet$een 2) to )1 c,t Ainterpolated #aluesC. I,M VG 100 satis!ies this" see Fig. 17.21
he e3ui#alent grade !rom chart in Fig. 17.22" ,27 %0 oil comes under this range and is
recommended !or the operation.
ISO GG GRADE LHBRICAN'S
F!"1721 G!scos!t5 'e#4er$ture cur+e 0or ISO GG "r$ded o!ls
SAE OIL GISCOSI'I C2AR'
F!"1722 G!scos!t5 'e#4er$ture cur+es o0 SAE "r$ded o!ls
7 Losses !n "e$r %o&es :
otal po$er loss 1 . 1
t
B 1
ch
B 1
b
B 1
s
1
t
J po$er loss at tooth engagement.
1
ch
J churning po$er losses

+ J

+ J

1
b
J bearing po$er losses S 1sJseal !rictional po$er loss.
L
=
-

81
+
8*
@-
t
J cosK G
+
2

1
L
=
*88
81
+

=
8*

=
,** @-
t
27 cos *.
O
27*
+
2

L
c)
= c % G
288GL

J
1 2
8.
& 18
*
@-
'here
V J peripheral speed Am6sC
b J !ace $idth o! the gear AmmC
c J !actor e3ual to 0.00( !or splash lubrication" 0.00+ !or stream lubrication
J Viscosit- o! oil at the operating temperature Ac8C
L
c)
= c % G
288GL

J
1 2
8.
& 18
*
@-
L
=
8881&78&27*&

2
=
88&27*&*.

8.
&18
*
= 8,** @-
c)
27
+
18.

1
b
. ).2% x 10
J*
F !
b
d n &'
$here
F J radial load on the bearing A?C
!
b
J coe!!icient o! !riction at the bearing reduced to the sha!t diameter 0.00) J 0.01 !or
rough estimation or re!er to catalog.
d J sha!t diameter AmmC
n J sha!t speed ArpmC
From the catalog !
<
. 0.002 !or roller bearings and 0.00% !or ball bearings.
<earings at 2 S <
1
b
. ).2% x 10J* F !
b
d n
. ).%%x10J*x 1)920x0.002 x 9)x2()0 .0.21* &'
<earings at D S 7
1
b
. ).2% x 10
J*
F !
b
d n
. ).%%x10
J*
x 1)920x0.00% x7)x*19.(2. 0.1)1&'
1
<
. 0.%+( &'
,eal !rictional po$er loss4
1
s
.
s
U x10
J%
&'
'here
s
seal !riction tor3ue
U R angular #elocit- o! the sha!t.
F!" 172* Fr!ct!on torDue $t +$r!ous te#4er$ture 0or n!tr!le ru%%er
S t54e o!l se$l/ S)$0t d!$#eter .8##/ s4eed 1888 r4#

s
. ! 8
r
r
'here r . radius o! the sha!t HmI
! R seal !riction
8
r
R =adial lip load H?I
Coe!!icient o! !riction4 !
!. ; AV # b 6 8
r
C
16%
; . Characteristic ?umber
V . Mil Viscosit- H?.s6cm
2
I
# . 1inear ,peed Hm6sI
b . 1ip Contact 'idth HmI
Fig. 17.2% gi#es the tor3ue #s temperature chart !or seal. 1et the outlet oil temperature
be +)
o
C
2t +)
o
C"
s
.0.17?m !rom Fig.17.2%a
V . Wdn6+0000 . Wx)0x10006+0000 . 2.%+ m6s
he operating Velocit- V . Wx9)x2()06+0000 . +.() m6s

s
at operating speed o! pinion sha!t speed . 0.17 x A+.()62.%+C
16%
.0.299 ?m
Gr$4) 172*$ Fr!ct!on torDue $t +$r!ous te#4er$tures 0or n!tr!le ru%%er
S t54e o!l se$l/ S)$0t d!$#eter .8 ##/ s4eed 1888 r4#
8inion sha!t seals po$er loss
1
s
.
s
U x10
J%
. 0.299x%0*.77 x 2 x10
J%
. 0.1)1 &'
Gear sha!t seal po$er loss
V . W x 7)x*19.(26+0000 . %.2 m6s

s
. 0.17 A%.262.%+C
16%
. 0.1** ?m
1
s
.
s
U x10
J%
. 0.1** A%0*.776%.+2Cx2x10
J%
. 0.0%2 &'
otal seal !riction . 0.1)1 B 0.0%2 . 0.1*% &'.
otal po$er loss in the gearbox4
1 . 1
t
B 1
ch
B 1
b
B 1
s
. 9.%% B 0.9%% B 0.%+( B 0.1*% . ).%1) &'
For the operating speed o! the gear 27.%% m6s" the suggested t-pe o! lubrication is oil Xet
lubrication.
2ssuming inlet oil temperature o! 90
o
C and outlet oil temperature o! +)
o
C" the oil suppl-
rate has to be4
Y
e
. 1 x 10
%
6 Z c [ . A).%1)x10
%
6 0.**x1+70x2)C .0.1997 lps .0.01997x+0.*.+* lpm.
<ased on the details o! the gearbox" the sha!t details are $or&ed out. he detailed
pinion sha!t dra$ing is sho$n in Fig.17.29 and that o! the gear sha!t in Fig.17.2). he
corresponding re#ised dimensions o! the pinion and gears are sho$n in Fig.17.2+ and
17.27.
F!"172, 9!n!on s)$0t dr$(!n" #$ter!$l C ,. )$rdened $nd te#4ered to *38 B)n
F!"172. Ge$r s)$0t dr$(!n" #$ter!$l duct!le !ron 128=78=82 )$rdened to **1 B)n
F!"1721 9!n!on %l$n@ re+!sed dr$(!n" s)o(!n" $ll t)e d!#ens!ons
F!"1727 Ge$r %l$n@ re+!sed dr$(!n" s)o(!n" $ll t)e d!#ens!ons.
'$%le 171 Det$!ls o0 t)e "e$r%o&
Gearbox siOe S $t 79)x2+0x1020 mm
%%0 &g
M, $elded
construction
8inion C9) steel $ith
hardness %*0 <hn
>obbed and ground
Gear ductile iron grade
1206(0602 o! hardness %%1
<hn
>obbed and ground
,ha!ts CJ9) hardened
and tempered and
ground
1ubricant ,27 %0 Mil Xet lubrication 10 lpm \ . (*.2D
he gearbox is o! split t-pe $ith radial assembl-. Gears and bearings are mounted on
the sha!ts separatel- outside and assembled radiall- in the gearbox and the top co#er is
bolted in position. he oil Xet and the outlet connections are made subse3uentl-. * lpm
oil is directed at the gear mesh and 2 lpm is directed at the bearings and seals.
he gearbox assembl- #ie$s are sho$n in Fig. 17.2* to 17.%0. he !ront #ie$
separatel- and end #ie$ are sho$n separatel- in Fig 17.2* and Fig. 17.2( !or clarit-.
he assembl- #ie$ !ront and side together is sho$n in Fig.17.%0.
F!"1723 Front +!e( o0 t)e $sse#%l5 o0 t)e "e$r%o&
F!"1727 End +!e( o0 t)e "e$r%o&
F!"17*8 Asse#%led +!e( o0 t)e )el!c$l "e$r%o&
---------------------------------