8/28/2015 Design procedure of Gear Box for automobile and machine tools

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Design procedure of Gear Boxfor automobile and machinetools

Updated: 20‐

May‐2015

Category: Mechanical

Projects

Author: Paresh

Gujarati

Member

Level: GoldPoints: 60

This resource gives complete design of Gear Box.

This includes step by step guide to design of each

components of Gear Box. These include gear design,

shaft design, casing design as well as other

important parts of Gear Box. Read the complete

article to get the details.

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8/28/2015 Design procedure of Gear Box for automobile and machine tools

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Importance of Gear Box

What is Gearbox? A Gear Box is actually a speed

variable device which changes the speed of power

transmission device according to the requirements of

torque. We normally use various power transmission

devices like lathe machine, drilling machine, milling

machine or any other machine tools which require

power at different torque or speed as per the will of

operator or based on the operation performed. High

torque operations require low speed and vice verse.

E.g. when we drive vehicle at steeper road, we lower

the speed to have increased torque. Power and torque

are directly proportional but speed and torque are

inversely proportional according to formula:

Power transmitted = 2 x PI﴾=3.14159﴿ x Speed x

Torque/60.0 Watt

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Hence, to perform different operations that require

different torque or power and thus, we can fulfil the

requirements by changing the speed. This speed

variation can be done by using different gear having

different teeth cut on it on various shafts at proper

distance to have perfect mesh in between the two

gears. In case of lathes, milling machines the speeds

are fixed by the required cutting feed and/or cutting

speed for a range of materials. Low strength materials

can be cut at higher speed and high strength material

required higher torques so that speed needed is very

low compared to that of low strength materials. Also

in case of auto‐mobiles maximum and minimum

speeds of the vehicle determines the size of gearbox.

Those students who are in final year mechanical

engineering, can take Gear Box design as their final

year project. You can refer to various other options for

final year project topics here.

Design procedure for Gear Box

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Follow this procedure to have idea about how to

design a complete Gear Box with each component's

individual design.

1. Determine the maximum and minimum speeds

of the output shaft. Calculate the number of

steps or speed reduction stages for this range.

This depends on the application as well as space

optimization. Higher reduction stages require

more space because of more number of gears

and shafts requirements.

2. Select the type of speed reducer or gear box

based on the power transmission requirements,

gear ratio, positions of axis, space available for

speed reducer. Also make sure that for low gear

ratio requires single speed reduction. Select

worm gears for silent operation and bevel gears

for intersecting axis.

3. Determine the progression ratio which is ratio

maximum speed and minimum speed of output

shaft of Gear Box. The nearest progression ratio

should be a standard one and is taken either

from R 20 or R 40 series.

4. Draw the structural diagram and kinematic

arrangement indicating various arrangement

possibilities during speed reduction or

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increment.

5. Select materials for gears so that gear should

sustain the operating conditions and operating

load. Normally cast iron is chosen for housing

and cast steel or other alloy can be selected as

per the load requirements.

6. Note down the maximum power out put in Horse

Power ﴾H.P﴿ or transmission power and

revolution per minute of shart i.e. rpm of each

shaft.

7. Determine the centre distance between the

driven and driver shaft based on the surface

compressive stress.

8. Determine the module of gear by beam strength

as well as fix the number of teeth required.

9. Calculate the diameter of the shafts by torque

requirements and bending moment

considerations.

10. Calculate the key size, shape or type of

transmission keys for each gears.

11. Select appropriate fit and tolerance for mating

parts like shaft and gear.

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12. Select bearings types based on the loading and

operating conditions. Also make sure to include

consideration of maximum speed and expected

life of gears and gear box. Normally ball bearings

and roller bearings are used for small size of

gearbox because they have lower thrust

requirement due to low speed reduction.

13. Make the shaft stepped or provide collar to

prevent axial displacement of bearing and gear.

14. Provide suitable clearance between gears and

walls of the housing of gear box and based on

this considerations design the casing/housing of

gearbox.

15. Complete the design of casing. One should

Provides fins if necessary to have increased heat

transfer by convection and conduction. Put

inspection hole/man hole as well as drain hole to

drain lubricating oil. Also provide oil level

indicator to have proper amount of oil during

operation, if not put, this will lead to failure of

gear and shaft due to over heating or due to

frictional failure. Provide transportation hooks for

transporting the gearbox from one place to

another or during installation and maintenance.

Also design gear changing lever accordingly.

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16. Draw neat and clean working drawings in

suitable software like AutoCAD, Pro Engineer etc.,

indicating required details during manufacturing

or assembly.

17. One can also perform finite element analysis of

the complete Gear Box after it completely

designed.

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Responses to "Design procedure of Gear Box for

automobile and machine tools"

Author: Muhammedaneez  21 Nov 2012   Member

Level: Gold   Points : 4

Nowadays all have their own vehicles. Most of them

are aware about the common parts of their vehicle.

But they are not aware of the most important part of

the vehicles which is gear box. Gear box plays a great

Share

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role in the manufacturing of vehicles. In appropriate

changing of gears will affect the engine of the vehicle

and it will also reduce the mileage of the vehicle. So it

is important to know about the gear box of the vehicle

and its function. This article will be helpful for those

studyies. This will be a helpful topic for mechanical

students for their projects, assignments and also for

improving their knowledge.

Author: Paresh Gujarati  21 Nov 2012   Member Level:

Gold   Points : 3

Yes, Muhammedaneez, you are right. This project

deals with complete Design subject that is covered in

entire Mechanical Engineering during bachelors. This

project includes design of each principal element like

shaft, key, gears, housing, hook as well as material

selection. This is just a reference how you can cover

complete Machine Design subject during your project

work in final year.

Guest Author: valiya shailesh   21 Apr 2014

I am p.g student my project based on gear box so

please send a report of gear box design.

Guest Author: Ashwini   02 Nov 2014

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Please send me the report.

Guest Author: Samuel   14 May 2015

It is very nice article.

Guest Author: Alffy   07 Jun 2015

Would you please send the formulas to calculate in

the gearbox design.....

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