3.3.

Conceptual Design

Fig.10. Conceptual design of a three stage constant mesh gear box

3.4. Embodiment Design
3.4.1. Design of Gears
E
A C

D F
B
Fig.11.Simplified 2D picture of 3 speed stage constant mesh gearbox
Given Parameters
 Manual transmission
 Power: 30kw
 Speed: 2000rpm
 Speed stage: 3
With the given parameters of power, speed, and the number of speed stages, we can proceed to
determine the gear ratios and then calculate the number of teeth on each gear.
Determine gear ratios
Since there are 3 speed stages, we can assume each stage provides a reduction in speed.
Let’s assume a typical gear ratio progression for a 3-speed gearbox, such as 1:1, 1.5:1, and 2:1. i.e,
These ratios are commonly used in automotive transmission. [42]
Number of teeth and speed of each gear
Using the 3𝑟𝑑 Gear ratio:
In order to determine number of teeth of each gear, firstly we need to get the number of teeth of gear ‘A’
because, and we can get it from the following table.
 Table 1. Minimum number of teeth on the pinion. [43]

Since, The tooth profile of the 1 14 /2° full depth involute system was developed for use with gear hobs
for spur and helical gears [43]. We choose the number of teeth of gear ‘A’ 32.
 Teeth Number
𝑠𝑝𝑒𝑒𝑑𝑜𝑓𝑑𝑟𝑖𝑣𝑒𝑟 𝑡𝑒𝑒𝑡ℎ𝑜𝑓𝑑𝑟𝑖𝑣𝑒𝑛
Gear ratio (G.R) = =
𝑠𝑝𝑒𝑒𝑑𝑜𝑓𝑑𝑟𝑖𝑣𝑒𝑛 𝑡𝑒𝑒𝑡ℎ𝑜𝑓𝑑𝑟𝑖𝑣𝑒𝑟

𝑇𝐵
G.R3 = 𝑇𝐴
𝑇𝐵
1 = 32

TB = 32
𝜔𝐴
G.R3 = 𝜔𝐵

 Speed
2000
𝜔𝐵 = 1

𝜔𝐵 = 2000rpm
Using the 1𝑠𝑡 Gear ratio:
 Teeth Number
TA+TB=TC+TD=TE+TF …………………………………. (eq 1)
𝑇𝐸
G.R1 = 𝑇𝐹
𝑇𝐸
2 = 𝑇𝐹

TE = 2TF …………………………………………... (eq 2)

Now substitute equation2 in to equation1, therefore:
TA+TB=TE+TF
32+32=2TF+TF
64=3TF
64
TF= 3
 TF=21.33
TF≈22
Now in order to find TE, substitute the value of TF in to equation2
TE=2TF
TE=2(22)
TE=44
𝜔𝐴 𝜔𝐹
G.R1 = 𝜔𝐵=𝜔𝐸
𝜔𝐴
G.R1 = 𝜔𝐸

 Speed
𝜔𝐴
𝜔𝐸 = 𝐺.𝑅1
2000𝑟𝑝𝑚
𝜔𝐸 = 2

𝜔𝐸 = 1000rpm
Using the 2𝑛𝑑 Gear ratio:
 Teeth Number
TA+TB=TC+TD=TE+TF …………………………………. (eq 3)
𝑇𝐶
G.R2 = 𝑇𝐷
𝑇𝐶
1.5 = 𝑇𝐷

TC = 1.5TD ………………………………………... (eq 4)

Now substitute equation4 in to equation3, therefore:
TA+TB=TC+TD
32+32=1.5TD+TD
64=2.5TD
64
TD= 2.5

TD=25.6
TD≈26
Now in order to find TC, substitute the value of TD in to equation4
TC=1.5TD
 TC=1.5(26)
TC=39
𝜔𝐴 𝜔𝐷
G.R2 = 𝜔𝐵= 𝜔𝐶
𝜔𝐴
G.R2 = 𝜔𝐶

 Speed
𝜔𝐴
𝜔𝐶 = 𝐺.𝑅2
2000𝑟𝑝𝑚
𝜔𝐶 = 1.5

𝜔𝐶 = 1,333.33rpm
Therefore, values of the number of teeth we get from the above calculations are:
TA=32, TB=32, TC=39. TD=26, TE=44, and TF=22

ωB=ωD=ωF=2000rpm, Since, they are mounted on the same shaft

Torque of each Gear
With a power of 30kw and a speed of 2000rpm, we can calculate the torque using the formula: 2𝜋 ×
2000𝑟𝑝𝑚
𝑃𝑜𝑤𝑒𝑟
Torque = 𝐴𝑛𝑔𝑢𝑙𝑎𝑟𝑆𝑝𝑒𝑒𝑑

30𝑘𝑤
Torque = 2𝜋×2000𝑟𝑝𝑚

30𝑘𝑤
Torque = 2000
2𝜋×
60

60×30,000
Torque = 2𝜋×2000

Torque = 143.24Nm = 143,240Nmm

Since, the 3𝑟𝑑 gear ratio is 1:1 the output torque has equal value with the input torque. Therefore;
TA=TB=143.24Nm
And, TB=TD=TF=143.24Nm, Since, they are mounted on the same shaft
𝑇𝐶 𝜔𝐷
=
𝑇𝐷 𝜔𝐶
𝜔𝐷
TC=TD 𝜔𝐶
2000𝑟𝑝𝑚
TC=143.24(1333.33𝑟𝑝𝑚)

TC=214.86Nm
 𝑇𝐸 𝜔𝐹
=
𝑇𝐹 𝜔𝐸
𝜔𝐹
TE=TF𝜔𝐸
2000𝑟𝑝𝑚
TE=143.24(1000𝑟𝑝𝑚)

TE=286.48Nm
The geometry of Helical gear
Let : - modulus of gear m=5
- Number of teeth=T
 Pressure angle in the plane of rotation, φ = 15° to 25° [43]
 Helix angle, ψ = 20° to 45°
 Circular pitch =Pc=𝜋×m=𝜋×5=15.7
 Normal pitch (Pn): = P ×cos φ =15.7×cos20=14.75mm/teeth
 Addendum(A) = 0.8×m= 0.8×5=4mm
 Dedendum (Dd) =1×m =1×5mm=5mm
 Working depth=2×m=2×5mm=10mm
 Minimum total depth = 1.8×m=1.8×5=9mm
 Minimum clearance = 0.2×m=0.2×5mm=1mm
 Thickness of tooth = 1.5708×m=1.5708×5=7.854mm.
 Face width(b) = b=4Pc=4 𝜋m
b=4 𝜋m
b=4 𝜋5mm
b=62.83mm
For gear ‘A’:
Pitch circle diameter
Based on these parameters, we can calculate the pitch diameters of the given gears using the formula:
Pitch Diameter (Dp)=Number of teeth(T) × Module(m)
Where: Module is the size of the gear (pitch circle diameter divided by the number of teeth)
Dp,A=TA × m
Dp,A=32 × 5mm
Dp,A=160mm
Outer Diameter (Do):
We can calculate the face width of the given gears using the formula: Do=Dp+2A=Dp+8mm
Do=Dp,A+8
Do=160mm+8mm
Do=168mm
Base circle Diameter (Db):
We can calculate the face width of the given gears using the formula: Db=Dpcos25°
Take in volute angle ψ=25°
Db=Dp,Acos25°
Db=160mm × cos25
Db=145mm
peripheral velocity (v):
We can calculate the face width of the given gears using the formula: v = π D.N = π m.T.N
V=π mTANA
V= π 5mm×32×2000
𝑚𝑚
V=1005309.65𝑚𝑖𝑛
𝑚
V=16.755𝑠𝑒𝑐

For gear ‘B’:

Pitch circle diameter
Dp,B=TB × m
Dp,B=32 × 5mm
Dp,B=160mm
Outer Diameter (Do):
Do=Dp,B+8
Do=160mm+8mm
Do=168mm
Base circle Diameter (Db):
Db=Dp,Bcos25°
Db=160mm × cos25
Db=145mm
peripheral velocity (v):
v = π DP.NP = π m.TP.NP
V=π m.T.N
V= π 5mm×32×2000
𝑚𝑚
V=1005309.65𝑚𝑖𝑛
𝑚
V=16.755𝑠𝑒𝑐

For gear ‘C’:

Pitch circle diameter
Dp,C=TC × m
Dp,C=39 × 5mm
Dp,C=195mm
Outer Diameter (Do):
Do=Dp,C+8
Do=195mm+8mm
Do=203mm
Base circle Diameter (Db):
Db=Dp,Ccos25°
Db=195mm × cos25
Db=176.73mm
peripheral velocity (v):
v = π DP.NP = π m.TP.NP
V=π m.T.N
V= π 5mm×39×1333.33
𝑚𝑚
V=816812.04𝑚𝑖𝑛
𝑚
V=13.1𝑠𝑒𝑐
 For gear ‘D’:
Pitch circle diameter
Dp,D=TD × m
Dp,D=26 × 5mm
Dp,D=130mm
Outer Diameter (Do):
Do=Dp,D+8
Do=130mm+8mm
Do=138mm
Base circle Diameter (Db):
Db=Dp,Dcos25°
Db=138mm × cos25
Db=125mm
peripheral velocity (v):
v = π DP.NP = π m.TP.NP
V=π m.T.N
V= π 5mm×26×2000
𝑚𝑚
V=785398.1634𝑚𝑖𝑛
𝑚
V=13.1𝑠𝑒𝑐

For gear ‘E’:

Pitch circle diameter
Dp,E=TE × m
Dp,E=44 × 5mm
Dp,E=220mm
Outer Diameter (Do):
Do=Dp,E+8
Do=220mm+8mm
Do=228mm
Base circle Diameter (Db):
Db=Dp,Ecos25°
Db=220mm × cos25
Db=199.38mm
peripheral velocity (v):
v = π DP.NP = π m.TP.NP
V=π m.T.N
V= π 5mm×44×1000
𝑚𝑚
V=691150.38𝑚𝑖𝑛
𝑚
V=11.52
𝑠𝑒𝑐

For gear ‘F’:

Pitch circle diameter
Dp,F=TF × m
Dp,F=22 × 5mm
Dp,F=110mm
Outer Diameter (Do):
Do=Dp,F+8
Do=110mm+8mm
Do=118mm
Base circle Diameter (Db):
Db=Dp,Fcos25°
Db=118mm × cos25
Db=106.94mm
peripheral velocity (v):
v = π DP.NP = π m.TP.NP
V=π m.T.N
V= π 5mm×22×2000
𝑚𝑚
V=691150.38𝑚𝑖𝑛
𝑚
V=11.52𝑠𝑒𝑐
Force Analysis

Fig.12.Tooth forces acting on a right-hand helical gear.[44]

Figure 12 is a three-dimensional view of the forces acting against a helical-gear tooth. The point of
application of the forces is in the pitch plane and in the center of the gear face. From the geometry of
the figure, the three components of the total (normal) tooth force W are: [44]
60000𝑃
Wt= 𝜋𝐷𝑜𝑁

Wr = W sin φn
𝑊𝑡
W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓

Wa = W cos φn sin ψ
 φ =20° as higher pressure angle can produce a smaller pinion with a complaining smaller and
based on the most widely used presser angle.[44]
 Helix angle (ψ) = 25°, the helix angle is always measured on the cylindrical pitch surface.
Values are not standardized but commonly range between 20° and 45°. Lower values give less
end thrust, but higher values tend to give smoother operation.[44]
tan φn =tan φ*cos ψ = tan 20*cos 25=0.33 then,
φn=𝑡𝑎𝑛−1 φn= 𝑡𝑎𝑛−1 (0.33)
φn=18.233
For gear (A, B)
60000𝑃 60000∗30𝐾𝑁
 Wt= 𝜋𝐷𝑜𝑁 = 𝜋∗168𝑚𝑚∗2000𝑟𝑝𝑚

Wt=1.7052KN=1705.2N
 Wb=Wt×cos ψ =1705.2N×cos25=1545.44N
𝑊𝑡 1705.2𝑁
 W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓=𝑐𝑜𝑠20∗𝑐𝑜𝑠18.233
 W=1910.56N
 Wr = W sin φn=1910.56N*sin18.233=597.78N
 Wa = W cos φn sin ψ =1910.56N*cos18.233*sin25=767N
For gear ‘C’
60000𝑃 60000∗30𝐾𝑁
 Wt= 𝜋𝐷𝑜𝑁 = 𝜋∗203𝑚𝑚∗1333.33𝑟𝑝𝑚

Wt=2.11684KN=2116.84N
 Wb=Wt*cos ψ=2116.84N*cos25=1918.5N
𝑊𝑡 2116.84𝑁
 W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓=𝑐𝑜𝑠18.233∗𝑐𝑜𝑠25

W=2459.14N
 Wr = W sin φn=2459.14N*sin18.233=769.42N
 Wa = W cos φn sin ψ=2459.14N*cos18.233*sin25=987.09N
For gear ‘D’
60000𝑃 60000∗30𝐾𝑁
 Wt= 𝜋𝐷𝑜𝑁 = 𝜋∗138𝑚𝑚∗2000𝑟𝑝𝑚

Wt=2.07593KN=2075.93N
 Wb=Wt*cos ψ=2075.93N*cos25=1881.43N
𝑊𝑡 2075.93𝑁
 W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓=𝑐𝑜𝑠18.233∗𝑐𝑜𝑠25

W=2411.62N
 Wr = W sin φn=2411.62N*sin18.233=754.55N
 Wa = W cos φn sin ψ=2411.62N*cos18.233*sin25=968.023N
For gear ‘E’
60000𝑃 60000∗30𝐾𝑁
 Wt= 𝜋𝐷𝑜𝑁 = 𝜋∗228𝑚𝑚∗1000𝑟𝑝𝑚

Wt=2.51297KN=2512.97N
 Wb=Wt*cos ψ=2512.97N*cos25=2277.52N
𝑊𝑡 2512.97𝑁
 W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓=𝑐𝑜𝑠18.233∗𝑐𝑜𝑠25

W=2919.33N
 Wr = W sin φn=2919.33N*sin18.233=913.4N
 Wa = W cos φn sin ψ=2919.33N*cos18.233*sin25=1171.81N
For gear ‘F’
60000𝑃 60000∗30𝐾𝑁
 Wt= 𝜋𝐷𝑜𝑁 = 𝜋∗118𝑚𝑚∗2000𝑟𝑝𝑚

Wt=2.42778KN=2427.78N
 Wb=Wt*cos ψ=2427.78N*cos25=2200.3N
𝑊𝑡 2427.78𝑁
 W=𝑐𝑜𝑠𝜑𝑛𝑐𝑜𝑠𝜓=𝑐𝑜𝑠18.233∗𝑐𝑜𝑠25

W=2820.36N
 Wr = W sin φn=2820.36N*sin18.233=882.44N
 Wa = W cos φn sin ψ=2820.36N*cos18.233*sin25=1132.1N
Strength analysis of helical gear
In helical gears, the contact between mating teeth is gradual, starting at one end and moving along the
teeth so that at any instant the line of contact runs diagonally across the teeth. Therefore, in order to
find the strength of helical gears, a modified Lewis equation is used. It is given by:[44]
WT = (σo × Cv ) b.π m.y'
where,
WT = Tangential tooth load,
σo = Allowable static stress,
Cv = Velocity factor,
b = Face width,
m = Module, and
y' = Tooth form factor or Lewi’s factor corresponding to the formative or virtual or equivalent number
of teeth.
For gear ‘A and B’
15
The value of velocity factor (Cv) is taken as: Cv = 15+𝑣 , since its peripheral velocity is 16.755m/s, so
it is in range of from 10 m / s to 20 m / s.
15 15
Cv = 15+𝑣 = 15+16.755

Cv = 0.4724
Formative or equivalent number of teeth on a helical gear, TE = T / cos3 α
where T = Actual number of teeth on a helical gear, and
α = Helix angle
TE = TA,B / cos3 α
TE = 32/ cos3(25)
TE = 42.98
Tooth form factor
y'P = 0.175 – 0.841/TE
y'P = 0.175 – 0.841/42.98
y'P = 0.1554
Therefore,
WT = (σo × Cv ) b.π m.y'
WT = (385 × 0.4724) 62.83mm × π × 5mm × 0.1554
WT = 27893.86N
The dynamic tooth load on the helical gears is given by: WD = WT + 21. 𝑣.
WD = WT + 21. 𝑣.
= 27893.86N + 21 × 16.755
WD = 45049.64N
The static tooth load or endurance strength of the tooth is given by: WS = σe .b.π m.y'
WS = 385 × 62.83mm × π × 5mm × 0.1554
WS = 59047.115N
For gear ‘C’
15
The value of velocity factor (Cv ) is taken as: Cv = 15+𝑣 , since its peripheral velocity is 13.1m/s, so it
is in range of from 10 m / s to 20 m / s.
15 15
Cv = 15+𝑣 = 15+13.1

Cv = 0.5338
Formative or equivalent number of teeth on a helical gear, TE = T / cos3 α
where T = Actual number of teeth on a helical gear, and
α = Helix angle
TE = TC / cos3 α
TE = 39/ cos3(25)
TE = 52.4
Tooth form factor
y'P = 0.175 – 0.841/TE
y'P = 0.175 – 0.841/52.4
y'P = 0.1588
Therefore,
WT = (σo × Cv ) b.π m.y'
WT = (385 × 0.5338) 62.83mm × π × 5mm × 0.1588
WT = 32208.96N
The dynamic tooth load on the helical gears is given by: WD = WT + 21. 𝑣.
WD = WT + 21. 𝑣.
= 32208.96N + 21 × 13.1
WD = 49887.2N
The static tooth load or endurance strength of the tooth is given by: WS = σe .b.π m.y'
WS = 385 × 62.83mm × π × 5mm × 0.1588
WS = 60339N
For gear ‘D’
15
The value of velocity factor (Cv) is taken as: Cv = 15+𝑣 , since its peripheral velocity is 13.1m/s, so it
is in range of from 10 m / s to 20 m / s.
15 15
Cv = 15+𝑣 = 15+13.1

Cv = 0.5338
Formative or equivalent number of teeth on a helical gear, TE = T / cos3 α
where T = Actual number of teeth on a helical gear, and
α = Helix angle
TE = TC / cos3 α
TE = 26/ cos3(25)
TE = 34.9
Tooth form factor
y'P = 0.175 – 0.841/TE
y'P = 0.175 – 0.841/34.9
y'P = 0.1509
Therefore,
WT = (σo × Cv ) b.π m.y'
WT = (385 × 0.5338) 62.83mm × π × 5mm × 0.1509
WT = 30606.6N
The dynamic tooth load on the helical gears is given by: WD = WT + 21. 𝑣.
WD = WT + 21. 𝑣.
= 30606.6N + 21 × 13.1
WD = 47574.77N
The static tooth load or endurance strength of the tooth is given by: WS = σe .b.π m.y'
WS = 385 × 62.83mm × π × 5mm × 0.1509
WS = 57337.256N
For gear ‘E’
15
The value of velocity factor (Cv ) is taken as: Cv = 15+𝑣 , since its peripheral velocity is 11.52m/s, so
it is in range of from 10 m / s to 20 m / s.
15 15
Cv = 15+𝑣 = 15+11.52

Cv = 0.5656
Formative or equivalent number of teeth on a helical gear, TE = T / cos3 ψ
where T = Actual number of teeth on a helical gear, and
ψ = Helix angle
TE = TC / cos3 ψ
TE = 44/ cos3(25)
TE = 59.1
Tooth form factor
y'P = 0.175 – 0.841/TE
y'P = 0.175 – 0.841/59.1
y'P = 0.16
Therefore,
WT = (σo × Cv ) b.π m.y'
WT = (385 × 0.5656) 62.83mm × π × 5mm × 0.16
WT = 34385.635N
The dynamic tooth load on the helical gears is given by: WD = WT + 21. 𝑣.
WD = WT + 21. 𝑣.
= 34385.635N + 21 × 11.52
WD = 52038.8N
The static tooth load or endurance strength of the tooth is given by: WS = σe .b.π m.y'
WS = 385 × 62.83mm × π × 5mm × 0.16
WS = 60794.97N
For gear ‘F’
15
The value of velocity factor (Cv ) is taken as: Cv = 15+𝑣 , since its peripheral velocity is 11.52m/s, so
it is in range of from 10 m / s to 20 m / s.
15 15
Cv = 15+𝑣 = 15+11.52

Cv = 0.5656
Formative or equivalent number of teeth on a helical gear, TE = T / cos3 ψ
where T = Actual number of teeth on a helical gear, and
ψ= Helix angle
TE = TC / cos3 ψ
TE = 22/ cos3(25)
TE = 29.5
Tooth form factor
y'P = 0.175 – 0.841/TE
y'P = 0.175 – 0.841/29.5
y'P = 0.1465
Therefore,
WT = (σo × Cv ) b.π m.y'
WT = (385 × 0.5656) 62.83mm × π × 5mm × 0.1465
WT = 31484.3N
The dynamic tooth load on the helical gears is given by: WD = WT + 21. 𝑣.
WD = WT + 21. 𝑣.
= 31484.3N + 21 × 11.52
WD = 47957.23N
The static tooth load or endurance strength of the tooth is given by: WS = σe .b.π m.y'
WS = 385 × 62.83mm × π × 5mm × 0.1465
WS = 55665.4N