calculations of the gears

Step 1: Speed ratio

Let the gear ratios be equal. Then it should be √ 12=3. 706 say 3.7
7
The reduction ratio at each pair is ¿
2
2 2
Final speed at this ratio of reduction ¿ 1440 × × =117.5
7 7
2.5
Difference ¿ ×100=2.08 % which is acceptable.
120

Step 2: Gear Teeth in the wheels

Let Gear 2 has 17 teeth
7
Then gear 3 will have ×17=59.5 twwth
2
N2 12
Therefore, Number of teeth
N3
N4
N5
[ ][ ]
= 59.5
12
59.5

Step 3: Power, Torque and Forces

t Power 1,000 ×60
Tangential force on gear 2 W 32= = =279 .3 N
Pitchline Velocity 48× π × 10−3 × 1440
The net force on the gear is ¿ W t32 ÷ cos ϕ=276.3 ÷ cos 20=28 4.04 N
Power 1,000 ×60
Torque on input shaft ¿ = =7 .63 Nm
Angular Velocity 1440 ×2 π

7
Torque in Gear 3 ¿ T 32=6.63× =26 .21 Nm
2
This torque is applied on the intermediate shaft between the gears 3 and 4.
The same force is applied by gear 3 on the intermediate shaft.

Assuming full power is delivered to output ie gear 5

1,000 ×10 3 ×3.5 × 3.5
Force on gear 4 W t45 = =98 7.08 N
π × 168× 24
Net force on gear 4 ¿ W t45 ÷ cos ϕ=3868÷ cos 20=1029.1 N
1,000× 3.5× 3.5
Torque on the output shaft ¿ =¿82.24 Nm
24 ×2 π

Step 4: Check for Bending and Contact Stresses

Contact Stress Consideration

Let us take AISI 1040 steel from Table A-21.
Also from Shigley page 221 equation 2.68 gives
SC =2.26 H B +179 MPa
¿ 2.26 ×262+179=771.12 MPa
Considering the Poisson’s ratio as 0.3, Young’s Modulus as 207,000 MPa and all gears are AISI 1040
Q&T

Gear 5 is the one that experiences the maximum force and therefore is considered.
1 1
1 1

[( ] [( ]
2 2
C p= = =190.27 MPa
1−μ2p 1−μ2g 1−0.32 1−0.32
π
Ep
+
Eg ( )) π +
(
207 ×10 3 207 × 103 ))
48
r 1= sin ∅=8.21 mm
2
168
r 2= sin ∅=28.73 mm
2
24
Pitch line velocity ¿ 168 × π × ×10−3=1.034 m/sec
3.5 × 3.5

6.1+1.034
Kv= =1.17
6.1

We assume Face Width F=20 mm

Bending stress consideration

According to Lewis’ Equation Maximum bending stress is given by
K vW t P
σ= where F = Face width and P is diametral pitch, Y is Lewis Factor and K v is as
FY
calculated earlier
6.1+1.034
Kv= =1.17
6.1

From table 14.2 the Lewis Factor Y is 0.245

Gear numbers Teeth Speed Ratio Pitch Radius Center Distance Speed (RPM)
2 12 24 1440
3 42 3.5 84 108 360
4 12 24 360
5 42 3.5 84 108 120

Gear 2 calculations:

Radi distance (λ+δ) Angle λ Angle δ Angle HOP X Y

us PQ Rad Rad Rad coordinat coordinat
 e e
2.582479 0.114509 0.114012 0.000496 2.638389 22.54615
22.7 503 054 461 592 0.116 402 048
8.208483 0.363970 0.349065 0.014904 3.132628 23.79467
24 44 234 85 384 0.131 613 667
10.78791 0.478344 0.446173 0.032170 3.690616 24.72608
25 919 325 467 858 0.148 066 649
12.93751 0.573658 0.520825 0.052833 4.368714 25.63034
26 137 835 774 06 0.169 814 005
16.59455 0.735814 0.634360 0.101454 6.040717 27.34062
28 333 783 586 197 0.217 109 429

Between Teeth Profile

29

27

25
Y-coordinate

Involute
23
Addendum circle
Dedundum
21
Mirror Involute

19

17
-8 -6 -4 -2 0 2 4 6 8
X-coorinate

Gear 3 calculations:

Radi distance (λ+δ) Angle λ Angle δ Angle HOP X Y

us PQ Rad Rad Rad coordinat coordinat
e e
3.224159 0.040846 0.040823 2.26933E 78.97997
79 53 177 484 -05 2.25E-02 1.78E+00 157
18.17677 0.230277 0.226332 0.003945 2.141480 80.97168
81 652 637 06 577 2.64E-02 019 68
25.65921 0.314296 0.010774 2.760934 82.95406
83 286 0.325071 115 885 3.33E-02 927 704
28.72969 0.363970 0.349065 0.014904 3.140860 83.94125
84 204 234 85 384 3.74E-02 319 92
86 34.13788 0.432485 0.408193 0.024291 4.68E-02 4.022232 85.90588
 518 46 776 683 387 831
38.90238 0.492845 0.457907 0.034937 5.051365 87.85490
88 045 816 9 917 5.74E-02 041 146

Between Teeth Profile

89
88
87
86
85
Y-coordinate

84 Series1
83 Series2

82 Series3

81 Series4

80
79
78
-6 -4 -2 0 2 4 6
X-coorinate

Shaft calculation
Step 6
Shaft design results should have 5 parts
1. General geometry form
2. Diameter calculations
3. Bending Moment calculations
4. Actual endurance calculations
5. Torque calculations

1 .General Geometry Form

For the input Shaft the Layout can be decided as
A – left end of shaft
B – Bearing in left end
C – The point in which the gear is fitted
D – Right hand bearing
Now look at the functions
i. Portion BCD is the part where the gear C is supported by the bearings B and D.
ii. From A to B the shaft carries a torque which is the input torque.
iii. At B there is a bearing that gives a reaction to the shaft.
iv. At C the gear is mounted on the shaft and it transmits the torque to gearwheel 3. It
also has the force exerted by wheel 3 and received by wheel 2.
v. Beyond that there is no torque.
vi. At D the shaft rests on the bearing D and has the reaction from the bearing.
Draw this information on the stick or line diagram.

From this we know that the bending moment is maximum at C and there is torque at this
point.
i. Starting from D a step is needed to lock the bearing without moving to the left. A
circlip is used to lock its movement to the right.
ii. Then at C another step is needed to lock the gear wheel from sliding to the left. A
circlip is used to lock its movement to the right.
iii. Then at B a step is needed to lock the bearing from moving to the right and reducing
the size of the bearing. A circlip is used to lock its movement to the left.
Therefore the geometry form of the shaft will be something like the one shown below:

2. Diameter Calculations
From Mott
1 /3

[ √( ) ( )]
Kt M 2 3 T 2
32 N
D= +
π S'n 4 Su
Where N is the safety factor
K t −¿StressConcentration Factor
S'n−¿Actual Endurance strength
S y−¿¿ Yield strength
M – Bending moment
T – Torque
3. Bending moment calculations

4. Actual Endurance Strength Calculations

Table 1

  Shaft 1 Shaft 3 Shaft 2  

Shaft diameter 0.012722797 0.019316953 0.023109883 meters
Bending moment 7.35 25.725 44.1  
Sn prime 218700000 218700000 218700000  
Su 779000000 779000000 779000000  
Safety Factor 2 2 2  
Stress concentration 3 3 3  

Input :

K t =3
N=2
C m=1
C R =0.9 ( reliability )=0.9
C st =1
Sn → AISI 1040=270 Mpa
Sa =779 Mpa
S y =593 Mpa
D1=48 ÷2=24 [shaft dia]
D 2=18

D2 −0.11
C s=D 1=D 2+6=( ) =0.9
7.62
S'n=S n C m C st C R C s=( 270 ×1 ×1 ×0.9 × 0.9 )=218.7 Mpa
T =6.63145 N .m
M =7.35109 N .m
D=0.0127 m
Bearing Calculations

Table 2

Beari Fd =          
ngs 1029.2
Xd 1036.8 296.2285 296.2285 84.63673  
714 714 469
C10(K 5.208126 3.430248 3.430248 2.259277 Divide by 2 for wach bearing and
N) 728 069 069 17 turn F to KN
   
Force Bore OD Width Fillet Shoulder ds Shoulder dH
(mm) Radius
4.94 10 30 9 0.6 12.5 27
5.2 10.25 30.25 9.125 0.6 12.5 27.125
7.02 12 32 10 0.6 12.5 28
Gearbox layout and bill of materials
CAD

a- Gears

b- Shafts
c- Bearing
d- Drawing of the assembly
e- Geometry of the assembly

f- Final product ( gear box )

Discussion and Learning Experience

At the end of the project we designed a 2 stage gear reduction that inputs 1440 rpm and
outputs around 120 rpm. While satisfying design requirements and constrains. At the end
the project proved success as shown in the results, as we designed a full gearbox from
scratch taking into account the design of gear, shaft, bearing, and cover design. As
mechanical engineers this great learning experience, since its crucial for mechanical
engineers to be able to machine design basic industrial components. We are now able to
design gears which is most important and used component in all industries and calculate
their exact specifications, by calculating number of teeth from desired reduction ratio, then
using the thread analogue and finding angle. Also we can design shafts with specific torque
handling and strain. Lastly, able to design bearings which are important in any moving shaft,
and find every component dimension. After designing each component we implement our
knowledge in CATIA to simulate it, to have an idea of looks and to design housing. In
conclusion, we consider this a great experience that was plentiful of knowledge and will
benefit us in our future careers.