ACKNOWLEDGMENT

ABSTRACT
LIST OF TABLES
LIST OF FIGURES
NOMENCLATURE

Table of Contents

.LITERATURE REVIEW...........................................................................................................................1

1.1.1. GEARBOX....................................................................................................................................1

1.1.2. SOFTWARE..................................................................................................................................1

1.1.3 MATLAB.......................................................................................................................................3

2.1. INPUT SPECIFICATION PARAMETERS.........................................................................................4

2.2. DESIGN FOR THE FIRST REDUCTION STAGE (BEVEL GEAR).................................................5

2.2.1. STRENGTH ANALYSIS FOR BEVEL GEARS..........................................................................7

2.2.2. DESIGN OF SHAFT FOR PINION OF BEVEL GEARS...........................................................13

2.2.3. KEY DESIGN FOR THE INPUT SHAFT..................................................................................15

2.2.4. SELECTION OF SUPPORT BEARINGS...................................................................................16

2.2.4.1. TYPES OF ROLLING CONTACT BEARING....................................................................16

2.2.4.2. SELECTION OF SUPPORT BEARINGS FOR THE INPUT SHAFT................................17

2.3. DESIGN FOR THE SECOND REDUCTION STAGE......................................................................20

2.3.1. DESIGN OF SPUR GEAR........................................................................................................20

2.3.1.1. GEAR GEOMETRY DESIGN OF SPUR GEARS..............................................................20

 2.3.1.2. STRENGTH ANALYSIS OF SPUR GEARS......................................................................21

2.3.2. DESIGN OF HELICAL GEAR...................................................................................................23

2.3.2.1. GEAR GEOMETRY DESIGN OF HELICAL GEARS.......................................................23

2.3.2.2. STRENGTH ANALYSIS OF HELICAL GEARS...............................................................24

CHAPTER ONE
INTRODUCTION

1.1. INTRODUCTION
Gearbox is one of the essential mechanical machines that have gears shafts bearings and
other mechanical parts. And designing of this machine is one of the main requirements of BS
D. student of mechanical engineer. In our university Mekelle this design is given to students
as a project from the beginning of this department. Designing gearbox is huge that needs high
stress from the designer and to design and to refer many reference books. Designing of this
machine is time taking, tedious and to boring to calculate, iterate and draw each and every
gears and parts of the gearbox. Lecturers give this project designing gearbox with their input
data for the designs and at the end checking of the design and calculation values of the
students is somewhat difficult and boring.
This machine can be designed by having some programs. The designing formulas and
procedures are programmed and can be designed so that any user can design any gearbox
simply by having the input data. This programming can be in software like matlab and here
in this thesis project the design of gearboxes using matlab programming codes is worked.
Since programming of gearbox designs for all of the gearbox types is too much huge and
takes time, the program in this project is only for the intersecting two stage gearboxes and
thus the general methodology and procedures in designing and programming of the gearbox
is here summarized.
 Fig.1.1.General procedures in creating and designing the program

1.2. LITERATURE REVIEW

1.2.1. GEARBOX

A gearbox is a mechanical method of transferring energy from one device to another and is used
to increase torque while reducing speed. Torque is the power generated through the bending or
twisting of a solid material. This term is used interchangeably with transmission.

Located at the junction point of a power shaft, the gearbox is often used to create a right angle
change in direction, as is seen in a rotary mower or a helicopter. Each unit is manufactured with
a specific purpose in mind and the gear ratio used is designed to provide the level of force
required. This ratio is fixed and cannot be changed once the box is constructed. The only
possible modification after the fact is an adjustment that allows the shaft speed to increase, along
with a corresponding reduction in torque.

In a situation where multiple gear speeds are needed, a transmission with multiple gears can be
used to increase torque while slowing down the output speed. This design is commonly found in
automobile transmissions. The same principle can be used to create an overdrive gear that
increases output speed while decreasing torque.

1.2.2. SOFTWARE

Computer software, or just software, is a collection of computer programs and related data that
provides the instructions for telling a computer what to do and how to do it. Software refers to
one or more computer programs and data held in the storage of the computer for some purposes.
In other words, software is a set of programs, procedures, algorithms and its documentation
concerned with the operation of a data processing system. Program software performs the
function of the program it implements, either by directly providing instructions to the computer
hardware or by serving as input to another piece of software. The term was coined to contrast to
the old term hardware (meaning physical devices). In contrast to hardware, software "cannot be
touched". Software is also sometimes used in a more narrow sense, meaning application software
only. Sometimes the term includes data that has not traditionally been associated with computers,
such as film, tapes, and records.

Computer software is so called to distinguish it from computer programs, which encompasses the
physical interconnections and devices required to store and execute (or run) the software. At the
lowest level, executable code consists of machine language instructions specific to an individual
processor. A machine language consists of groups of binary values signifying processor
instructions that change the state of the computer from its preceding state. Programs are an
ordered sequence of instructions for changing the state of the computer in a particular sequence.
It is usually written in high-level programming languages that are easier and more efficient for
humans to use (closer to natural language) than machine language. High-level languages are
compiled or interpreted into machine language object code. Software may also be written in an
assembly language, essentially, a mnemonic representation of a machine language using a
natural language alphabet. Assembly language must be assembled into object code via an
assembler.
1.2.3 MATLAB
MATLAB (matrix laboratory) is a numerical computing environment and forth-generation
programming language. Developed by Math Work, MATLAB allows matrix manipulations,
plotting of function and data, implementation of algorithm, creation of user interfaces, and
interfacing with programs written in other languages, including C, C++, Java, and Fortran.

Although MATLAB is intended primarily for numerical computing, an optional toolbox uses the
MuPAD symbolic engine, allowing access to symbolic computing capabilities. An additional
package, Simuling, adds graphical multi-domain simulation and Model-Based design for
dynamic and embedded systems.

In 2004, MATLAB had around one million users across industry and academia. MATLAB users
come from various backgrounds of engineering, science, and economics. MATLAB is widely
used in academic and research institutions as well as industrial enterprises.
CHAPTER TWO
MANUAL GEARBOX DESIGN

Manual design of the two stage intersecting gearbox is necessary for the comparison of the
matlab programmed calculation values of the design. For comparison of both the spur and helical
gear designs in the second stage the input parameters are of two types.

2.1. INPUT SPECIFICATION PARAMETERS

Manual design of the two stage intersecting gearbox is necessary for the comparison of the
matlab programmed calculation values of the design. For comparison of both the spur and helical
gear designs in the second stage the input parameters are of two types (a and b).

The following four inputs are needed to choose the designing two stage intersecting reduction
gearbox among the different gearbox and gear types.
The driving shaft input power:
P1a=12 KW; P1b=22 KW
The driving shaft rotational speed:
N1a= 1200 rpm; N1b= 3000 rpm
The total gear ratio of the gearbox:
GR=8;
Therefore the following values are calculated to select the type of the gearbox and gears type.
Gear ratio at first reduction stage
1
GR 1=1/¿) =1/(1.25*(
√ 8
¿ ¿=2.26

Gear ratio at second reduction stage

GR 8
GR 2= = =3.53
GR 1 2.26
Rotational speed at larger gear first reduction stage

N 1a 1200 N 1 b 3000
N 2 a= = =531 rpm; N 2 b= = =1327.4 rpm
GR 1 2.26 GR 1 2.26
Rotational speed at pinion gear second reduction stage
N 3 a=N 2 a=531rpm∧N 3 b=N 2b=1327.4 rpm
Rotational speed at larger gear second reduction stage
N 3 a 531 N 3b
N 4 a= = =150.4 rpm; N 4 b= =248 rpm
GR 2 3.53 GR 2
Power at the second reduction stage (due to lose at the first stage gears):
P 2 a=0.96∗P 1 a=11.52 KW ; P 2 b=0.96∗P1 b=21.12 KW .
Pitch line velocity at first stage
v 1 a=0.11∗(P 1a∗N 1 a∗N 2 a)1/ 4=0.11∗(12∗1200∗531)1 / 4=5.78 m/s
v 1 b=0.11∗(P 1b∗N 1 b∗N 2 b)1/ 4=0.11∗(22∗3000∗1327.4)1 /4 =10.6 m/s
Pitch line velocity at second stage

1
4 m
v 2 a=0.11∗( P 2 a∗N 3 a∗N 4 a ) =3.4
s

1
4 m
v 2 b=0.11∗( P 2 b∗N 3b∗N 4 b ) =6.26
s
Therefore from the above calculation for the first input data the pitch line velocity at the second
reduction stage, v2a, is less than 5 m/s and thus the gears at the second stage are spur gears.
Similarly having the second input data the v2b is greater than 5 m/s and thus the gears at the
second reduction stage are helical gears.

2.2. DESIGN FOR THE FIRST REDUCTION STAGE (BEVEL GEAR)

The gears at the first reduction stage are the bevel gears and in designing bevel gear the
following input data are necessary in for this design.
Number of teeth for the pinion of the bevel gear (n1) =12
Module for the first stage reduction gears (m12) = 4 mm
p=pressure angle of the gears geometry (p) = 200
Fig.2.1. Terms and nomenclature used in bevel gear [1]
Then dimensions of teeth of the designed bevel gears are calculated here.
Pitch circle diameter of the pinion bevel gear
DPB 1=n1∗m12=12∗4=48 mm
Pitch circle diameter of the second bevel gear
DPB 2=GR 1∗DPB 1=2.26∗48=108.48 mm
Number of teeth for the second gear
n 2=n1∗GR 1=12∗2.26=27.12=28
Addendum of first and second gear
a 12=m12=4 mm
Dedendum of first and second gears
d 12=1.2∗m12=1.2∗4=4.8 mm
Clearance
c 12=0.2∗m12=0.2∗4=0.8 mm
Working depth
wd 12=2∗m12=2∗4=8 mm
Thickness of the tooth
tt 12=1.5708∗m12=1.5708∗4=6.3 mm
Pitch angle of the pinion gear

x 1=tan −1 ( GR1 1 )=tan ( 2.261 )=23.87

−1 0

Pitch angle of the larger gear

x 2=tan −1 ( GR 1 )=tan−1 ( 2.26 )=66.160

Pitch cone radius of the pinion gear

DPB 1 48
PR 1= = =59.3 mm
2∗sind ( x 1 ) 2∗sin 23.87
Pitch cone radius of the larger gear

DPB 2 108.48
PR 2= = =59 mm
2∗sind ( x 2 ) 2∗si66.16
Addendum angle of the pinion

y 1=tan−1 ( PRa 121 )=tan ( 59.34 )=3.86

−1 0

Addendum angle of the gear

a 12
y 2=tan−1 ( PR2 )=tan ( 594 )=3.88
−1 0

Dedendum angle of the pinion

z 1=tan −1 ( PRd 121 )=tan ( 59.3

−1 4.8
)=4.63 0

Dedendum angle of the gear

d 12 4.8
z 2=tan −1 ( )
PR 2
=tan −1
59 ( )
=4.650

Outside diameter of the pinion

DOB 1=DPB 1+2∗a 12∗cos ( x 1 )=48+2∗4∗cos ( 23.83 ) =55.3 mm
Outside diameter of the gear
DOB 2=DPB 2+2∗a 12∗cos ( x 2 )=108.64 +2∗4∗cos ( 66.16 )=111.85mm
Inside diameter of the pinion
DIB 1=DPB 1−2∗d 12∗cosd ( x 1 ) =48−2∗4.8∗cos ( 23.83 )=39.2 mm
Inside diameter of the gear
DIB 2=DPB 2−2∗d 12∗cosd ( x 2 )=108.46−2∗4.8∗cos ( 66.16 )=104.56 mm
Equivalent number of teeth for pinion
en 1=n1∗secd ( x 1 )=12∗sec ( 23.83 )=13.12
Equivalent number of teeth for gear
en 2=n 2∗secd ( x 2 )=27.15∗sec ( 66.16 ) =67.2

2.2.1. STRENGTH ANALYSIS FOR BEVEL GEARS

Selecting a suitable material for the bevel gears from table:
Material =Heat treated cast iron
Allowable static stress (Ho) = 196 MPa
Elastic young’s modulus (E) = 150 GPA
Brinell hardness number (BHN) = 300
Table2.1.Values of the allowable static stress of materials for the gears [1]
Material =Heat treated cast iron
Allowable static stress (Ho) = 196 MPa
Elastic young’s modulus (E) = 150 GPa
Brinell hardness number (BHN) = 300
Table2.2. Brinell hardness number, modulus of elasticity and modulus rigidity of materials of the
gears and shafts [2]

The type of application of the designing gearbox is also selected, but since all of the applications
are programmed the calculation is for all of the applications.
Table2.3. Service factor for different applications of the gearbox [1]
Peripheral velocity

pi∗DPB 1 a∗N 1a 3.14∗48∗1200

Vpla= = =3 m/ s
60000 60000

pi∗DPB 1 b∗N 1b 3.14∗48∗3000

Vplb= = =7.6 m/s
60000 60000

Velocity factor for teeth generated with precision machine

6 6 6 6
Cv 1 a= = =0.66 ; Cv 1 b= = =0.44 ;
6+ Vpla 6+3 6 +Vplb 6+7.6
Bevel factor i.e. slant height of the pitch cone

L= √ (DPB 1/2)2 +( D PB 2/2)2 ¿=√ (48/2)2+(108.48/2)2=59.3 mm

Tooth form factor or Lewis factor for pinion

Y 1=0.124− ( 0.912
en 1 )=0.124−(
0.912
13.12 )
=0.0545

Face width
b 12=8.35∗m 12=8.35∗4=33.4 mm
Center distance of the first reduction stage gears
( G R 12+1 )∗2∗L−b 12 (2.26¿¿ 2+1)∗2∗59.3−33.4
C 1= = =115.12 mm ¿
2∗GR 1 2∗2.26
Tangential load on the tooth in Newton
1∗L−b 12
WT 1a=( Ho∗Cv 1 a )∗b 12∗pi∗m12∗Y
L
¿ 196∗0.66∗33.4∗3.14∗4∗0.0545∗(59.3−33.4)/59.3
¿ 1294.7 N .
Wa 1a=WT 1a∗tan( p)∗c os( x 1)=1294.7∗tan 20∗cos 23.84=431 N
Similarly WT 1b=775 N .
Table2.4. Value of maximum allowable tooth error (e) in action versus pitch line velocity [1]

Having the pitch line velocity v1 the maximum allowable errors for both input data are:
ea=0.0525; and eb=0.08.
Dynamic tooth load
K1=0.111; a factor depending on the form of the tooth for 20 degree full depth tooth
Deformation factor
1∗ea 0.001∗.111∗0.0525
D 1 a=0.001∗K = =0.000437
1 1 1 1
+
Ep Eg ( ) +
150 150
D 1b=0.000666
Total dynamic load in Newton

21∗Vpla∗b 12∗D 1 a+WT 1 a

((
Wd 1 a= WT 1 a+
( 21∗Vpla+ ( √ b 12∗D 1 a+WT 1a ) )))
=2118.8 N

Wd 1b=1434.3 N
Static tooth load analysis
Flexural endurance limit or elastic limit stress
He 1=1.75∗BHN =1.75∗300=525
Static tooth load or beam strength or endurance strength
1∗L−b 12
(
Ws1= He 1∗b 12∗pi∗m12∗Y
L )
=¿5245.1 N

if strcmp(GF 1 ,' steadyloads ')

(1.25∗Wd 1 a)≤Ws 1
2648.5<5245.1 true
The material selected and gear dimensions are safe against tooth breakage.
Ws1
Th e safety factor will be SF 1 a= =1.98
(1.25∗Wd 1 a )
if strcmp(GF1,'pulsatinglo')
(1.35*Wd1a)<=Ws1
2860.4< 5242.5 true; safety factor=1.83
if strcmp(GF1,'shockingloa')
(1.5*Wd1a)<=Ws1;
3178.2<5242.5 true; SFa=1.65;
Wear tooth load
Ratio factor
2∗en 2
Q 1= =2∗¿ 67.17/(13.12+67.17)=1.67
en 1+ en 2
Surface endurance limit in MPa
Hes 1=( 2.8∗BHN −70 ) =2.8∗300−70=770 MPa
Load stress factor or material combination factor
1 1
Ks 1=
( + )∗Hes 1. ∗sin ( p )
Ep Eg
2

1400

(¿ 1501 + 1501 )∗770 ∗sin ( 20 ) =1.93

2

1400

Maximum or limiting load for wear in Newton’s

Ww 1=DPB 1∗b 12∗Q1∗Ks1=48∗33.4∗1.67∗1.93=5167.3 N

Wd1<Ww1
2118.8 <5177.13; true
SAFE to resist wear
Ww 1 5177.13
SF 2= = =2.44
Wd 1 2118.8
2.2.2. DESIGN OF SHAFT FOR PINION OF BEVEL GEARS
Materials for the shafts and key of the gearbox design are selected from the table below. The
table is selected from different books based on their properties, since shaft needs materials that
have ultimate tensile strength from 520 up to 760 MPa and are tabulated.
Table2.5. Properties of materials for the shafts and keys of the designing gearbox [1,2]

Plain carbon steel 15% C 390 320

Plain alloy steel 20%C 440 370
Plain carbon steel 30% C 520 440
Plain carbon steel 35% C 550 460
Plain carbon steel 40% C 520 290
Plain carbon steel 45% C 590 310
Plain alloy steel 50% C 620 340
Plain carbon steel 60% C 680 370
Carbon steel 44% C 646 358
Carbon steel 12% C 424 193

The materials selected for all the shafts and keys are materials with ultimate tensile stress
between 560 and 760 MPa and with yield strength of between 320 and 390 MPa. The input shaft
material is cold drawn plain carbon steel with 35% carbon and with permissible stress, Hu of 550
MPa.
Maximum permissible working stress:
Hps=0.29∗Hu=0.29∗550=159.5 MPa
Maximum permissible shear stress
Sps=0.18∗Hu=0.18∗550=99 MPa
Torque acting on the pinion
 a∗60000 12∗60000
T 1 a=P1 = =95.54 Nm
2∗pi∗N 1a 2∗3.14∗1200

b∗60000 22∗60000
T 1 b=P1 = =70 Nm
2∗pi∗N 1b 2∗3.14∗3000

b 12=8.35∗m 12=8.35∗4=33.4 mm
1∗2∗L−b 12 48∗2∗59.3−33.4
Rm=DPB = =17.24 mm
4∗L 4∗59.3
Tangential load at the mean diameter of the pinion

T 1 95.54
WTb 1= = =5.54 N
Rm 17.24

Fig.2.2. Forces acting on teeth of bevel gear [1]

Horizontal axial load
Wr h=WTb 1∗tan ( p )∗sin ( x 1 ) =5.54∗tan 20∗sin 23.82=0.8144 N
Vertical radial load
Wrv=WTb 1∗tand ( p )∗cosd ( x 1 )=1.845 N
Axial load
Wa=WTb 1∗tan( p)∗cos (x 1)=5.54∗tan 20∗cos 23.84=1.844 N
Assuming that the shaft is subjected to fluctuating loads
Overhang (distance between center of the gear and center of bearing)
Ro 1=15+0.5∗b 12=15+ 0.5∗33.4=31.7 mm
Bending moment due to radial load
Mbr 1=( Wrv∗Ro 1−Wr h∗Rm ) =44.44 Nm
Bending moment due to tangential load
Mbt 1=WTb 1∗Ro 1=5.54∗31.7=175.62 Nm
Resultant bending moment
MRb 1= √ Mbr 12 + Mbt 12= √ 44.442 +175.622=181.15 Nm
if eq(GF1,'steadyloads')
Km=1.5; Kt=1; end
if eq(GF1,'pulsatinglo')
Km=1.8; Kt=1.8; end
if eq(GF1,'shockingloa')
Km=2.5; Kt=2.3; end
Equivalent twisting moment
2 2 2 2
TE 1 s=√ ( Km∗MRb 1 ) + ( Kt∗T 1 ) =√ ( 1.5∗181.15 ) + ( 1∗95.54 ) =288 Nm
TE1p=377.1 Nm
TE1sh=515.3 Nm
Equivalent bending moment
ME 1 a=0.5∗ ( Km∗MRb 1+TE 1 )=0.5∗( 1.5∗181.15+ 288 )=279.87 Nm
According to maximum shear stress theory
D Ss=((16∗TE 1) /Sps∗pi)1/ 3=24.6 mm
According to maximum normal stress theory
DSb=((32∗ME 1) /Hps∗pi )(1 /3)=26.14 mm
Therefore taking the maximum one the input shaft diameter will be 26.14 mm.
Shear and moment diagram for the input shaft
Wv1=1.8144; Wh1=0.8144; Wa1=1.844; as1=30; bs1=55; cs1=46.7; Rbp=16.7;
 Fig.2.3.Supporting reaction forces and vertical and axial bending moment diagrams for the input shaft

2.2.3. KEY DESIGN FOR THE INPUT SHAFT

Selection of material for key is from the materials tabulated above for shafts
But select a material which is different from material of the shaft(less strength with its shaft)
The material selected for this key is cold drawn plain carbon steel of 15% carbon and with
ultimate tensile strength of 390 MPa. Thus
Maximum permissible working stress

Hps=0.29∗Hu=0.29∗390=113.1 MPa
Maximum permissible shear stress
Sps=0.18∗Hu=0.18∗390=70.2 MPa
 Fig.2.4. Standard dimensions of sunk rectangular key [1]
Therefore having the shaft diameter of 26 mm the dimensions of the key and key way on the
shaft are:
Width, w=10 mm
Thickness, t=8 mm
Length, l=1.571*DS1=1.571*26=40.84 mm
DS1=SDB1 (2);

Strength checking
Assuming the shear stress created in the key;
1∗60000000 12∗60000
TS 1=P = =95.54 Nm
2∗pi∗N 1 2∗3.14∗1200

. Sis=2∗TS 1/(l∗w∗DS 1)=2∗95 . 54/( 40 .84∗8∗26 )=2 . 02 MPa

Assuming the crushing (or compressive) stress induced in the key

4∗TS 1 4∗95.54
His= ( l∗t∗DS 1 ) 40.84∗8∗26
= =2.2 MPa

Since Sis<Sps && His<Hps

The material selected for the key is safe
2.2.4. SELECTION OF SUPPORT BEARINGS

2.2.4.1. TYPES OF ROLLING CONTACT BEARING

i. Ball bearing
a. Radial bearing: supporting the radial loads
 Single row deep groove bearing: for high load caring capacity and for high
running speed.
 Filling notch bearing: have more balls than single row deep groove
bearings thus used for larger load caring capacity
 Angular contact bearing: supporting both axial and radial loads and if they
are used in pairs they can carry thrust loads.
  Double row bearing: radial or angular contact between ball and rows that
have balls in pair. They can resist loads slightly less than twice that of
single row deep groove bearing.
 Self aligning bearing: permits shaft deflections within 2 to 3 degrees.
b. Thrust bearing : supporting the axial loads
ii. Roller bearing
a. Cylindrical roller bearing: rigid against radial motion. They have the lowest
coefficient of friction and are used in high speed service.
b. Spherical roller bearing: self aligning and they can carry thrust loads in either
direction.
c. Tapered roller bearing: they carry both radial and thrust loads.

( a) (b) (c) (d)

Fig.2.5.Rolling contact bearings (a. Deep groove ball bearing, b. Angular contact ball
bearing, c. Cylindrical roller bearing and d. Taper roller bearing) [1,3]
Generally the types of gears used in gearbox design are the rolling contact bearings not the
sliding bearings. And the type of supporting bearing selected for high speed shafts are the ball
bearings whereas for shafts with heavier loads the roller bearings are selected.
The working hours per day for the designing gearbox, Hr=20
The working days per year for the designing gearbox Dy=300
The working years (life in year) for the designing gearbox, Yr=10
 2.2.4.2. SELECTION OF SUPPORT BEARINGS FOR THE INPUT SHAFT
Bevel gears have both radial and thrust or axial loads acting on the bearing supports and since
the speed of input shaft is relatively high, thus the selected type of bearing for supporting the
input shaft inside the gearbox is Angular contact ball bearing.
In order to select the suitable bearing for an application the service life of the designing gearbox
is an important data and thus the working hours of the machines are decided by the user.
LH=Hr*Dy*Yr=20*300*10=60000 hrs; working hours
L=60*N1*LH=60*60000*1200=4.32*10^9; %rating life
k=3; constant for ball bearing.

Table2.6.The values of service factor for different applications of the gearbox [1]

if eq(GF1,'steadyloads')
Ks=1;
elseif eq(GF1,'pulsatinglo')
Ks=1.75;
elseif eq(GF1,'shockingloa')
Ks=2.25;
end
Cs 1=15+0.5∗b 12=31.4 mm
as 1=2.75∗Cs 1=86.35 mm
 Wrv∗Cs 1−Wr h∗Rm 2.2∗31.4−2.02∗17.5
RAv= = =0.4 N
as 1 86.35
RBv=Wrv−RAv=2.2−0.4=1.8 N
1∗Rm 5.5∗17.5
RA h=WTb = =1.12 N
as 1 86.35
RB h=WTb 1−RA h=5.5−1.12=4.38 N
RAa=Wr h=2.02 N
The maximum loads from the above calculated radial load values is 4.38 N and thus
WRs1=4.38 N
WAs1=RAa=2.02;
The rating load and each of the dimensions of the selected bevel gear are selected from standard
tables according to the diameter of the shaft. After the rating load is calculated this value is
compared with the standard tabulated rating load value. If the calculated rating load is greater the
matlab takes the dimensions according to the diameter of the shaft. But if it is less the
dimensions will be multiplied by some factor to resist the loads.
Having the shaft diameter of 26 mm the dimensions of the supporting bearing are:
Outside diameter, D1=67 mm
Width, H1=17.5 mm
Load rating, C1=19800;
WAs 1 2.02
e1=1.14; = =0.46 , t h us X =1∧Y =0;
WRs 1 4.38
Table2.7.X and Y values for the dynamic loads.[1]
Equivalent dynamic load (if the load is steadyloads)
WRR 1 s=Ks∗( X∗WRs 1+ Y∗WAs 1 ) =1∗( 1∗4.38+0∗0.56 ) =4.38 N
1
( L∗0.000001 ) k √3 4.32∗10 9∗0.000001
Cc 1= = =3.72 N
WRR 1 2.66
C1>=Cc1
Therefore the dimensions are safe.
And the type of bearing at the tip of the input shaft which fixes with the gearbox cover is single
row deep groove ball bearing, since the axial load from the bevel gears is supported by the one
inside bearing support.

2.3. DESIGN FOR THE SECOND REDUCTION STAGE

2.3.1. DESIGN OF SPUR GEAR

2.3.1.1. GEAR GEOMETRY DESIGN OF SPUR GEARS

The number of teeth for the pinion of the spur gear, n3=12
The module for the second stage reduction gears, ms=4
The pressure angle for the gears in degree, ys=200
Pitch circle diameter of the pinion bevel gear
DPB 3=n 3∗ms=12*4=48mm
Pitch circle diameter of the second bevel gear
DPB 4=GR 2∗DPB 3=3.53*48=169.44mm
Number of teeth for the second gear
n 4=n3∗GR 2=12*3.53=42.36
Addendum of third and fourth gears
as=ms=4mm
Dedendum of third and fourth gears
ds=1.25∗ms=1.25*4=5 mm
Clearance
cs=0.25∗ms=0.25*4=1 mm
Working depth
wds=2∗ms=2*4=8 mm
Minimum total depth
mtds=2.25∗ms=2.25*4=9 mm
Thickness of the tooth
tts=1.5708∗ms=1.5708*4=6.2832 mm
Fillet radius at root
frrs=0.4∗ms=0.4*4=1.6 mm
Face width
fws=14∗ms=¿14*4=56 mm
Minimum number of teeth to avoid interference
2∗as
np 3=
GR 2∗
(√( 1+
1
∗
1
(
GR 2 GR 2 ) 2
+ 2 ∗(sin ( ys)) −1 ) )
2∗4
np 3=
=3.01
3.53∗
( √( 1+
1
∗( 1
3.53 3.53 ) )2
+ 2 ∗(sin (20 °)) −1
)
n3>np3
No interference between teeth
Outside diameter of the pinion
DOB 3=DPB 3+2∗as=48+2*4=56 mm
Outside diameter of the gear
DOB 4=DPB 4+2∗as=169.44+2*4=177.44 mm
Inside diameter of the pinion
DIB 3=DPB 3−2∗ds=48-2*5=38 mm
Inside diameter of the gear
DIB 4=DPB 4−2∗ds=169.44-2*5=159.44 mm

2.3.1.2. STRENGTH ANALYSIS OF SPUR GEARS

The material selected for the designing spur gear is Heat treated cast iron with:
Permissible tensile stress, He2 =196 MPa
Elastic modulus, Eg=Ep =150 GPa
Brinell hardness number, BHN=300;

Vp 2= ( π∗DPB 3∗N 3
60000 )
Vp 2= ( π∗48∗531
60000 )
=1.3345m/s
Velocity factor for ordinary cut gears at velocities up to 12.5m/s
3 3
Cv 2= = =0.6921
3+Vp 2 3+1.3345
Tooth form factor or Lewis factor for pinion

Y 2=0.154− ( 0.912
n3 )=0.154−(
0.912
12 )
=0.078

Tangential load on the tooth

WT 2=( Ho∗Cv 2 )∗b 34∗pi∗ms∗Y 2
WT 2=(196∗0.6921)∗50∗3.14∗4∗0.078=6644.8N
Dynamic tooth load
ea=0.0525
K 2=0.111; A factor depending on the form of the tooth for 20 degree full depth tooth
Deformation factor
2∗e 0.001∗0.111∗0.0525
D 2=0.001∗K =
1 1 1 1 =0.000437
+ +
Ep Eg 150 150
Total dynamic load in newton
2∗b 34∗D2+WT 2
(
Wd 2= WT 2+ 21∗Vp
( 21∗Vp 2+ ( √ b 34∗D 2+ WT 2 ) ))
21∗1.3345∗50∗0.000437+6644.8
(
¿ 6644.8+
( 21∗1.3345+ ( √50∗0.000437+6644.8 ) ))
=8344.8N
Static tooth load analysis
Flexural endurance limit or elastic limit stress
He 2=1.75∗BHN =1.75*300=525MPa
Static tooth load or beam
Ws 2=He 2∗b 34∗pi∗ms∗Y 2
¿ 525∗50∗3.14∗4∗0.078
=25717N
Strength or endurance strength
if strcmp(GF1,'steadyloads')
 (1.25*Wd2)<=Ws2
1043.1<25716.6 ; true
The material selected and gear dimensions are safe against tooth breakage
Ws2
SF 3= =2.46
1.25∗Wd 2
if strcmp(GF1,'pulsatinglo')
(1.35*Wd2)<=Ws2
11265<25716.6; true
The material selected and gear dimensions are safe against tooth breakage
25716.6
SF 3= =2.28
11265
if strcmp(GF1,'shockingloa')
(1.5*Wd2)<=Ws2;
12517<25716.6;` true
The material selected and gear dimensions are safe against tooth breakage
25716.6
SF 3= =2
122517
Wear tooth load
Ratio factor
2∗GR 2 2∗3.53
Q 2= = =1.558
GR 2+1 3.53+1
Surface endurance limit in MPa
Hes 2=2.8∗BHN −70=2.8*300-70=770MPa
Load stress factor or material combination factor
1 1
Ks 2=
( + )∗Hes 2 ∗sin ( ys )
Ep Eg
2

1400

(= 1501 + 1501 )∗770 ∗sin ( 20 ° )

2

1400
=3.86
Maximum or limiting load for wear in Newton
Ww 2=DPB 3∗b 34∗Q2∗Ks 2
 =48∗50∗1.558∗3.86
=14431.38N
if Wd2<Ww2; (8344.8<14431.38 true)
SAFE to resist wear
14431.38
SF 4=Wd 1 ¿ 1= =1.72 ;
8344.8

2.3.2. DESIGN OF HELICAL GEAR

2.3.2.1. GEAR GEOMETRY DESIGN OF HELICAL GEARS

The number of teeth for the pinion of the helical gear n3=12
The module for the first stage reduction gears mh=4
The helix angle of the gears in degree xh=20
The pressure angle for the gears yh= 20
The dimensions of the designed helical gears are
Pitch circle diameter of the pinion gear

DPB 3=n 3∗mh=12*4=48mm

Pitch circle diameter of the larger gear
DPB 4=GR 2∗DPB 3=3.53*48=169.44 mm
Number of teeth for the larger gear
n 4=n3∗GR 2=12*3.53=42.36 mm
Addendum of third and fourth gears
a h=0.8∗mh=0.8*4=3.2
Dedendum of third and fourth gears
d h=mh=4 mm
Clearance
c h=0.2∗m h=0.2*4=0.8 mm
Working depth
wd h=1.8∗m h=1.8*4=7.2 mm
Thickness of the tooth
tt h=1.5708∗m h=¿1.5708*4=6.2832 mm
Axial pitch
pc=π∗m h=3.14*4=12.56 mm
Normal pitch
pn= pc∗cosd ¿) = 12.56*cos d(20° )= 11.8 mm
The minimum face width
b h=2.32∗pi∗mh/ tan¿) =2.32∗3.14∗4 /tan ¿) =80 mm

The equivalent number of teeth

ne 3=n 3/(cosd ( x h))3=12/( cosd (20 °))3=14.46
Outside diameter of the pinion
DOB 3=DPB 3+2∗a h=48+2*3.2=54.4mm
Outside diameter of the gear
DOB 4=DPB 4+2∗a h=169.44+2*3.2=175.84mm
Inside diameter of the pinion
DIB 3=DPB 3−2∗d h=48-2*4=40mm
Inside diameter of the gear
DIB 4=DPB 4−2∗d h=169.44-2*4=161.44mm

2.3.2.2. STRENGTH ANALYSIS OF HELICAL GEARS

The material selected for the designing spur gear is Heat treated cast iron with:
Permissible tensile stress, He2 =196 MPa
Elastic modulus, Eg=Ep =150 GPa
Brinell hardness number, BHN=300;
Peripheral velocity

Vp 3= ( pi∗DPB 3∗N 3
60000 )
3.14∗48∗1327.4
¿
60000
=3.33m/s
Velocity factor for peripheral velocities from 5m/s to 10m/s
6 6
Cv 3= = =0.643
6 +Vp3 6+ 3.33
Tooth form factor or Lewis factor for pinion
Y 3=0.154−(0.912/ n 3)=0.154-(0.912/12) =0.078

Fig2.6.Face width and forces on helical gear [1]

Face width
b 34=2.3∗pi∗mh ./ tan(x h)=2.3∗3.14∗4 /tan (20° )=79.4

WT 3=(Ho∗Cv 3)∗b34∗pi∗mh∗Y 3
¿(196∗0.643)∗79.37∗3.14∗4∗0.078
=9799.6 N
Dynamic tooth load
eb = 0.08
A factor depending on the form of the tooth for 20 degree full depth tooth
K3=0.111
Deformation factor
D 3=0.001∗K 3∗e/(1/Ep+(1/ Eg))
¿ 0.001∗0.111∗0.08/( 1/150+(1/150))
=0.000666
Total dynamic load in Newton

3∗b 34∗D3∗(cos(x h))2 +WT 3

( (
Wd 3= WT 3+ 21∗Vp
21∗Vp 3+ √ b 34∗D 3∗(cos (x h))2+WT 3 )))
 2
21∗3.33∗79.37∗0.000666∗(cos (20)) + 9799.6
((
= 9799.6+
( 21∗11.771+ √ 79.37∗.000666∗(cos (20))2 +9799.6 )))
=11779 N
Static load analysis
Flexural endurance limit or elastic limit stress
He 3=1.75∗BHN =1.75*300=525 MPa
Static tooth load or beam strength or endurance strength
Ws3=|(He 3∗b 34∗pi∗mh∗Y 3)|

= 525∗79.37∗3.14∗4∗0.078=40823 N
if strcmp(GF1,'steadyloads')
(1.25*Wd3)<=Ws3
The material selected and gear dimensions are safe against tooth breakage')
Ws 3 40823
SF 5= = =2.77 ;
( 1.25∗Wd 3 ) 14724
if strcmp(GF1,'pulsatinglo')
(1.35*Wd3)<=Ws3
The material selected and gear dimensions are safe against tooth breakage')
SF 5=¿
if strcmp(GF1,'shockingloa')
(1.5*Wd3)<=Ws3
The material selected and gear dimensions are safe against tooth breakage')
Ws 3 40823
SF 5= = =2.3 ;
( 1.5∗Wd3 ) 17669
Wear tooth load
Ratio factor
Q 3=2∗GR 2/(GR 2+1)=2∗3.53/(3.53+1)=1.558
Surface endurance limit in MPa
Hes 3=(2.8∗BHN −70)=2.8*300-70=770
Load stress factor or material combination factor
yhn=atan ( tan ( xh )∗cos ( yh ) )=42.40
 1 1 .2∗sin ( y hn )
Ks 3=3∗ ( +
Ep Eg )
∗Hes 3
1400
=5.57

Maximum or limiting load for wear in Newton

Ww 3=|( DPB 3∗b 34∗Q 3∗Ks 3 )|=32577 N
if Wd3<Ww3
disp('SAFE to resist wear')
Ww 3 32577
SF 6= = =2.76
Wd 3 11779
CHAPTER THEREE
GEARBOX DESIGN USING MATLAB SOFTWAR

The full flow charts for the designing gearbox are explained in this chapter. But since the flow
chart in designing the tooth profile for the gears are almost the same there will be one
representative flow chart. And the same representatives will be explained for the other
components of the gearbox.

The following four inputs are needed to choose the designing two stage intersecting reduction
gearbox among the different gearbox and gear types.

To simply understand by the readers the input parameters to design the gearbox here are written
the form as in the programming matlab codes and are also written as an equation to differ from
the other.

P 1=Enter t h e driving s h aft input power ( KW ) :

N 1=Enter t h e driving s h aft rpm:

GR=Enter t h e total gear ratio of t h e gearbox ( please c h oose GR below 13):

Having the above input data and some calculations the pitch line velocity which is used to select
the type of gear for the second reduction stage is calculated by:
The general flow chart for programming the gearbox design is below. And the flow chart for
selecting and designing the gearbox parts are next from this syntax.
 Input data

A complete two
stage reduction
gearbox design

Fig.3.2.General flow chart diagram for the design

1
( )
v 2=0.11∗ ( P2∗N 3∗N 4 ) . 4 ……………………………….. [1]
Based on this value, if it is less than 5 m/s the spur gear is recommended but if it is greater the
gear at the second stage are helical gears.
Below is syntax used to select the type of gearbox, based on this if the user enters intersecting
the matlab continues, but if the input string is different from intersecting the matlab code
displays an error message which advises the user to choose intersecting only since the design is
only for that or tells to spell the word intersecting correctly.
GBtype=select t h e type of t h e gearbox ¿
If the user writes par or other data the matlab sends an error message to choose an intersecting

or to correctly spell the input code ∫ ¿ but if the input is an input code ∫ ¿ the programming
continues.
if eq (GBtype , ' intersecting ' )
if GR ≤12
¿ exclude worm gear design t h e total gear ratio ∈t h isdesign isless t h an 13.
The gears at the first reduction stage are the bevel gears and in designing bevel gear the
following input data are necessary in for this design.
n 1=Enter t h e number of teet h for t h e pinion of t h e bevel gear :
m12=Enter t h e module for t h e first stage reduction gears :
p=Enter t h e pressure angle of t h e gears geometry :
After the input data are received the program calls the function bevelgear which calculates the
geometrical dimensions of the bevel teeth and displays as a table.
Here are sample result dimensions of the bevel gear teeth having an input data of
n 1=12 , m12=4∧ p=20 0 are here:
T h e dimensions of teet h of t h e designed bevel gears are :
PinionGear
Pic h diameter( DPB):48.00 108.61
Number of teet h ( n ) :12.00 27.15
Addendum ( a ) :4.00 4.00
Dedendum ( d ) : 4.80 4.80
Clearance ( c ) :0.80 0.80
Working dept h ( wd ) : 8.008.00
t h ickness of toot h(tt ) :6.28 6.28
Pitc h angle ( x ) :23.84 66.16
Addendum angle ( y ) :3.85 3.85
Dedendum angle ( z ) :4.62 4.62
Pitc h cone radius ( PR ) :59.3759.37
Outside diameter ( DOB ) :55.32111.85
Inside diameter ( DIB ) :39.22104.73
Equivalen no . ofteet h ( en ) :13.1267.17
Having the teeth dimensions of the bevel gear the strength of the tooth will be checked to its
static, dynamic and wear loads as follows. But first the suitable material for the bevel gear is
selected from table which is displayed at the command window.
Material 1=Enter t h e material selected for t h e gears of t h e first stage (OCIC , MGCI , HGCI , HTCI , FCSC , FCS
For checking of strength of bevel gears the function strecheckbevel is called to the main
function.
STCH=strec h eckbevel(ST 1 , GB 1 , B 1);
w hile GR <13
After the material from the table is selected the mechanical properties of the materials are
executed as format below:
Fig.3.3.Flow chart for selection of materials
Checking of the strength of the gears is according to the type of application. And at each step the
static and dynamic and the dynamic and wear loads are compared, if they are within the limit the
user will asked whether the safety factor on the calculation is satisfactory or not and if the user
enters ‘yes’ the program continues but input string is ‘not’ the program back to the selection of
materials. If the comparison is not fulfilled the matlab sends an error message to change the
selected material or to change the dimensions of the gears.
Since design must consider on the functioning of the designing gearbox, the type of application
of the designing gearbox must be selected first.
GF 1=Enter t h e type of lo ad application for t h e designing gearbox ¿
pulsatinglo∨s h ockingloa ¿ , please put t h e words as t h ey are written∈t h e parent h esis :

Fig.3.4. Selection of functionality of gearbox

The shafts for the gears are designed here. The materials for shafts and their key are selected
from displayed table of materials and their properties.

Materials h aft 1=Select t h e suitable material for t h e input s h aft ¿ t h e above table (PCS 15 , PAS 18 , PCS 30 , PCS
The function shft1bdesign is called and at this function the diameter of the shaft is calculated
according to both the maximum shear stress theory and maximum permissible stress theory.
SD1=[ Materialshaft 1 GF 1];
[SDB SDB 1]=shaft 1 bdesi gn (GB 1 , SD 1, B 1, GF 1) ;
The shear and moment diagrams are plotted in the matlab and the maximum moment is selected
for each of the shaft designs. Here the shaft is plotted with their correct dimensions but scaled
and the shear loads and their moment diagrams both the vertical and horizontal bending moment
diagrams are graphed.

Fig.3.5.Support forces and bending moment diagram of the input shaft

Shaft is designed by considering the load to be fluctuating loads so that their loads are multiplied
by having the fatigue and shock load factors. The designing shaft diameter will be the larger of
the calculated diameters from both stress theories.
Sprintf (' The shaft diameter ac cording¿maximum shear stress theory is % 3.2 f mm . ' , DSs);
DSb=((32∗ME 1) /Hps∗pi ).(1/ 3) ; % According¿ maximum normal stress theory
Sprintf ¿
normal stress theory is % 3.2 f mm .' , D if >(DSs , DSb)
DS 1=DSs ;
else
DS 1=DSb;
end
Next after the shaft is designed the key and keyway are designed here. The selection of material
for key is from the materials tabulated for shafts. But select a material which is different from
material of the shaft (less strength with its shaft).
Materialkeys 1= Enterthe material selected for the input shaft ( PCS 15 , PAS 18 , PCS 30 , PCS 35. ..) .
KDS 1=keydesigns 1(GB 1 , KM 1 , SDB 1)
After the function keydesigns1 is executed the design of key for the input shaft is followed. The
dimensions of key (sunk key) are selected from standard table after having the shaft diameter.
The scripts have standard key selections up to 150 mm diameter of the shaft.
But their strengths are checked as:
if Sis<Sps∧¿ His< Hps
disp(' T h e material selected for t h e key is safe ')
break (The loop terminates (continue programming))
else
disp(' UNSAFE please c h oose anot h er stronger material ')
continue (t h e loop return¿ select anot h er material)
end
Since the rotating shafts that carry gears needs support to stand on the gearbox cover they are
supported by bearings. Thus bearings are selected for each of the shafts according to their loads
and speed.
Generally the types of bearings used in gearbox design are the rolling contact bearings not the
sliding bearings. And the type of supporting bearing selected for high speed shafts are the ball
bearings whereas for shafts with heavier loads the roller bearings are selected.
In order to select the suitable bearing for an application the service life of the designing gearbox
is an important data and thus the working hours of the machines are decided by the user.
Hr=Enter the working hours per day for thedesigning gearbox
Dy=Enter the working days per year for thedesigning gearbox
Yr=Enter the working years(life∈ year )for the designing gearbox
Bevel gears have both radial and thrust or axial loads acting on the bearing supports and since
the speed of input shaft is relatively high, thus the selected type of bearing for supporting the
input shaft inside the gearbox is Angular contact ball bearing.
BS 1=bearing 1bselection(WH 1 , GB 1 ,GF 1 , SDB , SDB 1)
After the function bearing1bselection is executed the rating load is calculated by having the loads
from gear mesh and their loads. The service factor is included in the calculation which differs
with the gearbox functioning.
The rating load and each of the dimensions of the selected bevel gear are selected from standard
tables according to the diameter of the shaft. After the rating load is calculated this value is
compared with the standard tabulated rating load value. If the calculated rating load is greater the
matlab takes the dimensions according to the diameter of the shaft. But if it is less the
dimensions will be multiplied by some factor to resist the loads.
And the type of bearing at the tip of the input shaft which fixes with the gearbox cover is single
row deep groove ball bearing, since the axial load from the bevel gears is already supported by
the one inside ( bearing support).
Similar to the execution in the calculation of the rating loads in the selection of bearing above.
The following function is called and the rating loads are compared, and the dimensions of the
selected bearings are chosen.
if v< 5¿
five the second reduction st age gears will be spur gear ,but if this is greater the gears are helical gears .
If this condition is okay the matlab continues to design the spur gears as the second reduction
stage gears.
The spur gears are designed after the following input data are received from the user:
n 3=Enter thenumber of teeth for the pinion of the spur gear
ms=Enter themodule for the second stage reduction gears :
ys=Enter the pressure angle for the gears ∈degree(¿ 15¿25 degree) :
[S S 1]=spurgear (GB 2) ;
After the above function is called the matlab executes the calculation of the geometrical
dimensions of spur gear and each values displays.
The design also checks the interference between teeth by having the number of teeth and
minimum number of teeth of the design.
if np 3> n3
disp(' No interference between teet h' );
else
disp(' t h ere may be interference between teet h t h us you have ¿c h ange your numb er of teet h ' );
The strength of the designed spur gear is here checked but material for the gear is first selected
from the specified table.
Material 2=input ¿
designing spur gear (OCI , MGCI , HGCI , HTCI , FCSCH , FCSHT ...).
DSSG=strecheckspur (GB 1 ,GB 2, ST 2 , S 1)
Checking of the strength of spur gear is the same with that of the bevel gear above. The teeth are
checked to its static, dynamic and wear loads resistances.
Material for the middle shaft is selected from the specified table the diameter of the shaft is
calculated the some to the calculation in the input shaft by considering the load to be
fluctuating load and having the maximum shear stress theory and maximum permissible tensile
stress theory.
Materialshaft 2=Enter the material selected for the second shaft ¿ table 1.2( PCS 15 , PAS 18 , PCS 30 , PCS 35...):
SDB 3=shaft 2 sdesign(GB 1, GB 2 , SD 2 , B 1 , S 1 , DSSG)
The bending moment diagram of the programmed code for the intermediate shaft is plotted
having the input data the same with the data in design of gearbox manually.
 Fig.3.6.Supporting loads and bending moment diagrams of middle shaft
The larger diameter from the two calculation theories is selected and this will be displayed.
The selection of material for key is from the materials tabulated above for shafts and keys. But
select a material which is different from material of the shaft (less strength with its shaft)
Materialkeyss2=Enter thematerial selected for theintermediate shaft (PCS 15 , PAS 18 , PCS 30 , PCS 35. ..)
After the function keydesigns2 is called the dimensions of the key and keyway at the shaft are
selected and after these are checked to their strength the dimensions are displayed as (width,
thickness and length) in mm.
KDS 2=keydesigns 2(GB 1, KM 2 , SDB 2);
The type of bearing selected for supporting the middle shaft is based on the rotational speed of
the shaft, if speed is greater than 1000 rpm the bearing is angular contact ball bearing but if it is
less the bearing is taper roller bearing. The shaft carries bevel gear and spur gear and thus, it
have radial load from both gears and an axial load from the bevel gear.
The design of output shaft which supports the larger spur gear of the second reduction stage is
here addressed by first selecting the suitable material.
Materialshaft 3=Enter the material sele cted for the output shaft ¿ table 1.2(PCS 15 , PAS 18 , PCS 30 , PCS 35...)
[SDOS SDOS 1]=shaft 3 sdesign(GB 2 , SD 3 , S 1 , DSSG )
Design for the output shaft continues similar to the above calculations the diameter of the shaft is
calculated based on the maximum shear stress theory and maximum permissible tensile stress
theory and thus the designing shaft diameter will be the maximum of the two.
The selection of material for key is from the materials tabulated above for shafts. But select a
material which is different from material of the shaft(less strength with its shaft).
Materialkeyss3=Enter the material selected for the output shaft (P CS 15 , PAS 18 , PCS 30 , PCS 35...) .
KDS 3=keydesigns 3(GB 1 , KM 3 , SDOS)
The dimensions of the designing key is selected according to the dimension of the shaft and are
checked to their strength, if the key is safe the matlab continues but if not it returns back to select
another material.

The bearing selected for supporting the output shaft is the cylindrical roller bearing, since the
spur gears have only radial loads on their supporting bearing and the output shaft is with
relatively less speed
BS 3=bearing 3 sselections (WH 3 , GB 1 ,GF 1 , SDOS , SDOS 1 , B 1)
The dimensions of the selecting bearing are listed after the function bearing3ssekections is
called, selecting the dimensions with having shaft diameter and checking the rating loads with
the standards.
else ¿
jumps the spur gear d esign∧goes ¿ design of helical ¿
If the pitch line velocity is greater than 5 m/s, the matlab chooses the helical gears as the second
reduction stage gears.
For the design of helical gears the following four input data are required and are input from user.
n 3=Enter thenumber of teeth for the pinion of the helical gear :
mh=Enter the module for the first stage reduction gears :
xh=Enter thehelix angle of the gears∈degree (¿ 20¿45 degree)
yh=Enter the pressure angle for the gears∈degree (¿ 15¿25 degree)
[ H H 1]=helicalgear(GB 3)
The design of helical gear is the same to the other gears design but this design also checks the
face width of the designing gears to be with in some limit in order to have optimum pressure
angle and contact between meshing gears.
Material 3=Enter the material selected for thedesigning
spur gear ¿ the above(OCI , MGCI , HGCI , HTCI , FCSCH , FCSHT ...)
DSHG=strecheckhelical (GB 1 ,GB 3 , ST 3 , H 1)
The strength of the designed helical gears is checked to its static, dynamic and wears loads on the
tooth. And this comparison is done by considering the steady, pulsating and shocking load
applications.
The material for the intermediate shaft is selected from specified table the function shaft2hdesign
is called and the diameter of the shaft is calculated according to the two theories and assuming
the three types of application loads.
Materials h aft 2=Enter t h e material selected for t h e second s h aft ¿(PCS 15 , PAS 18 , PCS 30 , PCS 35...)
[SDOS 2 SDOS 3]=s h aft 2 hdesign(GB 1 , SD 2 , B 1 , H 1 , DSHG)
The selection of material for key is from the materials tabulated above for shafts and keys. But
select a material which is different from material of the shaft(less strength with its shaft).
The bending moment diagrams and the directions of the supporting loads are plotted here.

Fig.3.6.Supporting load directions and bending moment diagrams for output shaft
Materialkey h s 2=Enter t h e material selected for t h e intermediate s h aft (PCS 15 , PAS 18 , PCS 30 , PCS 35...)
KDS 4=keydesign h s 2( GB 1 , KM 4 , SDOS 3)
After the above function is executed the dimensions of the key and keyway are selected from
standard table having the shaft diameter and checked to their resistance to induced stresses. After
checking the dimensions are displayed.
The supporting bearing selected for the intermediate shaft is taper roller bearing, if the speed of
the shaft is less than 1000 rpm or Angular contact bearing, if the speed is greater, and since the
helical gears have both radial and axial loads on its support the bearings must resist thrust load.
[BS 3 BS 4 ]=bearing 2 hselection(WH 4 ,GB 1 , GF 1, SDOS 2 , SDOS 3 , B 1)

The dimensions of the selected bearings are displayed after the rating loads are calculated and
compared with the standard rating load values; if the calculated values are greater the program
continues but if this is not the dimensions in the standard table are multiplied by some factor in
order to sustain the induced rating load.
The material for the shaft is selected from the specified table and accordingly the function
written below is called. Then diameter of the output shaft is calculated with the same procedure
as in calculating the diameters before. And the larger diameter of the shaft will be displayed.
Materials h aft 3=Enter t h e material sele cted for t h e output s h aft ¿ table(PCS 15 , PAS 18 , PCS 30 , PCS 35...)
[SDOS 4 SDOS 5]=s h aft 3 hdesign(GB 3 , SD3 , H 1, DSHG)
The selection of material for key is from the materials tabulated above for shafts. But select a
material which is different from material of the shaft(less strength with its shaft).
Materialkeyhs3=Enter the material selected for the output shaft (PCS15, PAS18, PCS30,
PCS35...)
K DS5=keydesign h s 3(GB 1 , KM 5 , SDOS 5)
After the above function is executed the dimensions of the key and keyway are selected from
standard table having the shaft diameter and checked to their resistance to induced stresses. After
checking the dimensions are displayed.
The supporting bearing selected for the output shaft is taper roller bearing, since the helical gears
have both radial and axial loads on its support and the output shaft have relatively less rotational
speed.
BS 5=b earing 3 hselection (WH 5 , GB 1 ,GF 1 , SDOS 4 , SDOS 5 , B 1).
Fig.3.7.Schematic picture of two stage intersecting reduction gearbox
 CHAPTER FOUR

RESULT AND DISCUSSION

4.1. RESULTS

The gearbox is designed both manually and by having the matlab programming codes and having
the same input data in both designs their result are tabulated and compared here in this chapter.

Table.4.1.Results of the manual and programmed design of the gearbox

No. Name Result from Result from

manual(mm) matlab
1 Pitch circle diameter of the pinion bevel 48
gear
2 Pitch circle diameter of the second bevel 108.48
gear
3 Number of teeth for the second gear 28
4 Addendum of first and second gears 4
5 Dedendum of first and second gears 4.8
6 Clearance 0.8
7 Working depth 8
8 Thickness of the tooth 6.3
9 Pitch angle of the pinion gear 23.870
10 Pitch angle of the larger gear 66.160
11 Pitch cone radius of the pinion gear 59.3
12 Pitch cone radius of the larger gear 59
13 Addendum angle of the pinion 3.860
14 Addendum angle of the gear 3.880
15 Dedendum angle of the pinion 4.63 0
16 Dedendum angle of the gear 4.65 0
17 Outside diameter of the pinion 55.3
18 Outside diameter of the gear 111.85
19 Inside diameter of the pinion 39.2
20 Inside diameter of the gear 104.56
21 Equivalent number of teeth for pinion 13.12
22 Equivalent number of teeth for gear 67.2
23 slant height of the pitch cone 59.3
24 Face width 33.4
25 Center distance of the first reduction stage 115.12
gears
Loads on bevel gear
1 Tangential load on the tooth in Newton 1294.55 N
2 Deformation factor 0.000666
3 Total dynamic load in Newton 1351.82 N
4 Flexural endurance limit or elastic limit 525MPA
stress
5 Static tooth load or beam strength or 5242.5 MPA
endurance strength
6 The safety factor 1 3.22
7 Ratio factor 1.67
8 Surface endurance limit 770MPA
9 Load stress factor 1.93
10 Maximum or limiting load for wear in 5177.13
Newton
11 Maximum permissible shear stress 99MPA
12 Maximum permissible shear stress 95.54MPA
Tangential load at the mean diameter of the 5.54 N
pinion
13 Horizontal axial load 0.814
14 Vertical radial load 1.844 N
15 distance between center of the gear and 31.7
center of bearing
16 Bending moment due to radial load 44.44 Nm
17 Bending moment due to tangential load 175.62 Nm
18 Resultant bending moment 181.15 Nm
19 Equivalent twisting moment 288 Nm
20 Equivalent bending moment 279.87
21 Diameter of shaft According to maximum 24.5
shear stress theory
22 Diameter of shaft According to maximum 26.14
normal stress theory
23 Maximum permissible working stress 1131.1 MPa
24 Maximum permissible shear stress 70.2 MPa
25 Torque of shaft 1 95.54 Nm
26 Induced Shear stress 2.02 MPa
27 Induced bearing stress 2.2 MPa
Bearing’s dimension, rating load
1 Vertical Reaction force at A 0.4 N
2 Vertical Reaction force at B 1.8 N
3 Horizontal reaction force at A 1.12 N
4 Horizontal reaction force at B 4.38 N
5 Axial reaction force at A 2.02 N
6 Radial load on the bearing 4.38 N
7 Axial load on the bearing 2.02
8 Equivalent dynamic load 4.38 N
9 Calculated rating load 3.72 N
Design of spur gear
1 Pitch circle diameter of the pinion bevel 48
gear
2 Pitch circle diameter of the second bevel 169.44
gear
3 Number of teeth for the second gear 42.36
4 Addendum of third and fourth gears 4
5 Dedendum of third and fourth gears 5
6 Clearance 1
7 Working depth 8
8 Minimum total depth 9
9 Thickness of the tooth 6.2832
10 Fillet radius at root 1.6
11 Face width 56
12 Minimum number of teeth to avoid 3.01
interference
13 Outside diameter of the pinion 56
14 Outside diameter of the gear 177.44
15 Inside diameter of the pinion 38
16 Inside diameter of the gear 159.44
17 Peripheral velocity 1.3345
18 Velocity factor 12.5
19 Tooth form factor or Lewis factor for 0.078
pinion
20 Tangential load on the tooth 923 N
21 Deformation factor 0.000437
22 Total dynamic load in Newton 11322.35
23 Flexural endurance limit or elastic limit 525 MPa
stress
24 Static tooth load or beam 25716.6 N
25 Ratio factor 1.558

26 Surface endurance limit 770 MPa

27 Load stress factor or material combination 3.86
factor
28 Maximum or limiting load for wear in 14431.38 N
Newton
4.2. DISCUSSION

From this tabulated results it can be simply seen that there is no difference between the result of
the manually calculated and the values of the programming matlab codes. Thus having the
reference the manually worked out results the designing gearbox, the design and programming
codes of the programmed matlab are correct. The slight difference between results is because the
manually calculated values are somewhat reduced their significant figures and thus may result in
the approximated to some values.

CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

References