Design of Two stage gearbox

The geometrical proportions of a gear will depend on several factors. Normally, the following
parameters are given from which the designer has to proceed in his task.
1.
2.
3.
4.
5.
6.
7.

The output power or the torque required.

The transmission ratio.
The input speed or the required output speed.
The anticipated life of the gear set.
The duty or the service conditions.
The nature of load which the gear set is expected to encounter during its operational life
Other special conditions, such as, space requirements, pre-specified centre distance and
price limitations.

Accuracy of gears

The accuracy of the output of a gear depends on the accuracy of its design and manufacturing.
The correct manufacturing of a gear requires a number of prerequisite calculations and design
considerations. The design considerations taken into account before manufacturing of gears are:

Strength of the gear in order to avoid failure at starting torques or under dynamic loading
during running conditions.

Gear teeth must have good wear characteristics.

Selection of material combination.

Proper alignment and compactness of drive

Provision of adequate and proper lubrication arrangement.

We will now take up the individual data of gear parameters for proper design.
Material
Besides strength considerations, the choice of material mainly depends on the requirements of
space and weight and the overall price of the gear drive.
Cast iron is good enough for ordinary purposes.
Steel and cast steel offer better strength.
Pinion of synthetic material is quiet running and vibration damping.
Phosphor bronze and similar materials are used to alleviate the loss due to sliding.
The gear material should have the following properties:

High tensile strength to prevent failure against static loads

High endurance strength to withstand dynamic loads

Low coefficient of friction

Good manufacturability

Generally cast iron, steel, brass and bronze are preferred for manufacturing metallic gears with
cut teeth.
Where smooth action is not important, cast iron gears with cut teeth may be employed.
Commercially cut gears have a pitch line velocity of about 5 metre/second.

For velocities larger than this, gear sets with non-metallic pinions as one member are used to
eliminate vibration and noise. Non-metallic materials are made of various materials such as
treated cotton pressed and moulded at high-pressure, synthetic resins of the phenol type and
rawhide. Moisture affects rawhide pinions. Gears made of phenolic resins are self-supporting on
the other hand other two types are supported by metal side plates at both ends of the plate.
Large wheels are made with fretting rings to save alloy steels. Wheel centre is commonly cast
from cast iron. The ring is forged or roll expanded from steel of the respective grade specified by
the tooth design.
Number of Teeth
The number of teeth of the pinion and the gear are to be so chosen that a minimum value of
contact ratio 1.1 is assured.
For fast moving set, it should be greater than 1.5.

The transmission ratio should not preferably be a whole number to ensure hunting tooth action.
Guidelines for the selection of minimum number of teeth of pinion are given in Table 1.

Table 1 Minimum number of pinion teeth

When the number of teeth is below the minimum specified in Sec. 2.10, then obviously the pinion
is to be positively corrected.
To avoid interference:
14o full depth
20o full-depth

zmin = 32
zmin = 17

20o stub
zmin = 14
o
25 full-depth
zmin = 12
For the sum (or difference) of number of teeth of pinion and gear, the following rule holds good
For external gearing z1 + z2 >=24, and for internal gearing z2 z1 >=10
In a gear drive, two types of curves, the cycloidal and the involute, are generally used. In a gear
drive, the shape of the tooth depends upon the pressure angle. Gears of involute profile with
14.5, 20 full-depth and 20 stub pressure angles are most commonly used in industries. A 20
pressure angle full-depth involute gear tooth has various advantages over the other pressure
angles. BIS has recommended the use of 20 pressure angle full depth involute gear tooth

Transmission Ratio
If the transmission ratio is high, a multi-stage gear set is used to avoid unnecessarily big gears.
In general, the transmission ratio per stage is given by
i = 17 for general purpose drive
= 10 for maximum value in special cases
= 4 for maximum value for change-gear sets
If the given transmission ratio cannot be strictly adhered to for some technical ground, the
following deviations are allowed:
For all types of drives excluding worm-drive when i <= 250, the allowable deviation = +-3%
For all types of drives including worm-drive when i > 250, the allowable deviation = +-5%

ANALYZING GEARS FOR DYNAMIC LOADS

A two-stage, step-up gearbox drives a compressor and has a lubrication pump mounted on one of
the gear shafts, Fig. 1. Tables 1, 2, and 3 show the spur-gear data, tolerances for tooth errors, and
polar moments of inertia for the masses in the compressor drive. All gears in the drive have 20
pressure angles. The gears are made of steel; the compressor is made of cast iron. A 50-hp (37.3kW) motor drives the gearbox at 3550 rpm. What are the dynamic loads on this gearbox?

Figure 1: Two-stage step-up gearbox driving a compressor ( Machine Design.)

CONSTRUCTING
TRANSMISSIONS

MATHEMATICAL

MODELS

FOR

ANALYZING

HYDROSTATIC

Construct a mathematical model of vehicle performance for a construction vehicle powered by a

hydrostatic transmission when the vehicle is driven by a 45-hp (33.6-kW) engine at 2400 rpm,
with a high idle-speed of 2600 rpm. The vehicle has a supercharge pump rated at 2 hp (1.5 kW).
Other vehicle data are: loaded radius, r L = 14.5 in (36.8 cm); gross vehicle weight, W g = 8500
lb (3825 kg); weight on drive wheels, W w = 5150 lb (2338 kg); final drive ratio, R fd = 40:1;
coefficient of slip, C s = 0.8; and coefficient of rolling resistance, C r = 60 lb/1000 lb (27.2 kg/
454 kg) of gross vehicle weight. The vehicle is powered by a hydrostatic transmission with a 2.5in 3/rev (41-mL/rev) displacement pump, rated at 5000 lb/in 2 (34.5-MPa). Compare the
performance produced by using a 2.5-in 3/rev (41-mL/ rev) displacement fixed-displacement
motor and a 2.5-in 3/rev (41-mL/rev) displacement variable-displacement motor with an 11degree displacement stop. Other pump and motor data are given on performance curves available
from the pump manufacturer.
Calculation Procedure:

1. Determine the vehicle speed at maximum tractive effort

The theoretical pump displacement required to absorb the input horsepower from the engine,
using the nomenclature at the end of this procedure, is:

Substituting,

Next, find the horsepower-limited displacement from

Substituting,

Now we must find the pump flow from

Substituting,

Using the motor...

Section 22: Bearing Design and Selection

By Tyler G. Hicks (ed)
From Handbook of Mechanical Engineering Calculations, Second Edition
DETERMINING STRESSES, LOADING, BENDING MOMENTS, AND SPRING RATE IN
SPOKED BEARING SUPPORTS
Spoked bearing supports are used in gas turbines, large air-cooling fans, electric-motor casings
slotted for air circulation, and a variety of other applications. For the shaft and 6-spoked bearing
system in Fig. 1 having three rotor masses and these parameters and symbols,

Figure 1: Shaft and 6-spoked bearing system having three rotor masses. ( Product Engineering.)
SI values
P

= 10,000 lb (at either bearing)

(44,480 N)

Is

= 25 in 4

(1040.6 cm 4)

IR

= 0.3 in 4

(12.5 cm 4)

= 7 in 2 (for ring also)

(45.2 cm 2)

Es

= E R = 10 x 10" psi

(68,900 MPa)

= 10 in

(25.4 cm)

= 12 in

(30.5 cm)

CR

= 0.40 in

(8.9 cm)
(1.02 cm)
Symbols

SI values

A = spoke cross-section area, in 2

(cm 2)

C s = distance, neutral axis to extreme fiber (of spoke), in

(crn)

SI values
P

= 10,000 lb (at either bearing)

(44,480 N)

C R = distance, neutral axis to extreme fiber (of ring), in

(cm)

E R , E s = elasticity moduli (ring and spoke), psi

(kPa)

R RI = axial loading in inclined spokes, lb; (+ for upper two, ? for lower two)

(N)

F R2 = axial loading in vertical spokes, lb; (+ for top, ? for bottom)

(N)

F T =...