You are required to design a gearbox or speed reducer for an industrial saw that will cut tubing for

vehicle exhaust pipes to length prior to the forming process. The saw will receive 35 hp from the shaft
of an electric motor rotating at 1,750 rpm. The drive shaft for the saw should rotate at approximately
500 rpm (490 510 rpm is an acceptable range). The NEMA frame 284T motor will have a shaft
diameter of 1.875 in and a keyway to accommodate a 1/2x1/2 inch key. The attached table and figure
provide information about the motor. The saw is a band saw and generally operates in a smooth
manner, but moderate shock may be encountered as the saw blade engages the tubes or if there is any
binding of the blade in the cut. The minimum input torque to the saw should be 3,750 lb-in. The speed
reducer will be mounted on a rigid plate that is part of the base of the saw. The means of mounting the
reducer should be specified.

Flexible couplings may be used to connect the motor shaft to the input shaft of the reducer and a
suitable clutch is to be used to connect the output shaft directly to the shaft of the main drive wheel for
the band saw. The clutch should have a suitable engagement / disengagement mechanism. The design
of the band-saw shaft has not been completed but it is likely that its diameter will be the same as that of
the output shaft of the reducer. A compact size for the reducer is desirable, but space in the machine
base should be able to accommodate most reasonable designs. The factory owner is concerned about
the cost of building the speed reducer, and the cost should be considered when making design
decisions.

The saw is expected to operate 16 hours per day, 6 days per week, with a design life of at least 5 years.
This is approximately 25,000 hours of operation. The factory environment will have a temperature
range from 50
o
F to 100
o
F. The machine base will be enclosed and will prevent any unusual contact
with the reducer. However, the functional components of the reducer should be enclosed in their own
rigid housing to protect them from contaminants and to provide for the safety of those who work with
the equipment.


YOU ARE REQUIRED TO:

Choose a typical shaft in the reducer (only one shaft) and size all sections of the shaft. Specify
details of keyways, fillet radii, splines, bearing seats, etc.

Assume that the housing is fixed to the base by four bolts. Find the forces on the bolts and
appropriate size for the bolt.

Size other components (e.g., pulleys, sprockets, housing, etc.) as applicable without performing
detailed analysis.

Choose an appropriate clutch type along with an engagement / disengagement mechanism.
Write a brief paragraph justifying your choice. This is not covered in the class and requires
some independent research.


ABU-DHABI UNIVERSITY College of Engineering & Computer Science
Department of Mechanical Engineering MEC-430 Machine Design
Mini Project-2 (Teams of 2) Gearbox Design Due Date: Mon., May 26, 2014

Create an assembly drawing for one shaft (the shaft that you designed) showing how all
components fit together (shaft, bearings, gears, keys, housing, fasteners, etc.).

GENERAL NOTES:
Use appropriate software to make the technical drawings. You may use Ideas, AutoCAD, Pro-
Engineering, Solid Works or any other appropriate program.
All drawings should be on A4 sheets (21x29.7 cm) with standard layout.
Choose the appropriate type of drawing, number of drawings, sectional views, detailed views,
etc. that would adequately show your design.
Make reasonable assumption whenever needed, but make sure that they are necessary, and
make clear note of them in your report.

Best of luck to all of you!