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Design of Single Stage Reduction Gearbox
Design of Single Stage Reduction Gearbox
Introduction
Designing a mechanical power transmission such as a single stage spur gear gearbox is very
complex. The complexity arises from strong and often intractable interdependencies between
the design variable and system requirements. The optimal reducer is generally not an assembly
of components optimized in isolation a fact overlooked by many conventional designs. It is
known that designing of a reducer is an iterative process in which it is necessary to make some
tentative choices and to determine which parts of the design are critical For example, the
impact of certain choice of the coefficient of face width of the gear may yield to a minimum,
mass of gearing, but the selection of this coefficient may cascade through subsequent steps of
the design process (sizing of shafts, radial seals, ball bearings, housing etc.) that ultimately lead
to a heavier reducer than if a slight compromise had been made on the choice of the gearing.
Parameters
Gear 1
Gear 2
Number of teeth(N)
Form of teeth
Module (m)
Face with of teeth(F) (mm)
Pitch diameter(dp)(mm)
24
Involute
5.5
65
132
48
Involute
5.5
65
264
142.035
275.418
4.478
25.753
20
20
Gears
The gears were made from a material called EN C50 (tooth face hardened) which has a
allowable bending stress of 152 MPa , allowable contact stress of 1170 MPa, modulus of
elasticity 206000 MPa, and a Poissons ratio() of 0.3. The overall efficiency of the two gears is
98%.
Gear 1 (Pinion)
2864.8
1129.6
0
3079.4
10.367
2.7
7.6
190.99
Gear 2
2864.8
1129.6
0
3079.4
10.367
2.79
6.065
374.33
Shafts
The shaft holds everything together and it withstands most of the loads. Therefore, a
thorough statics analysis is required in order to design this component. Borrowing the statics
analysis already performed on the bearings, the shafts were analyzed. Shear Force and Bending
Moment diagrams were developed in order to determine the maximum points. The material
selected for the shaft is steel which has a modulus of elasticity of 206000MPa, modulus of
rigidity of 8000MPa and a density of 7860Kg/m3. The shaft and gear was fastened by the use of
keyway and the gear is held into place by circlips.
Bearings
The bearings are critical components that allow the system to move smoothly. They should also
withstand loading in the radial direction and thrust in the axial direction. In many application
roller bearings are used back to back in pairs for axial load . A statics analysis had to be
performed in order to find the reactions and determine the loads on the bearings. Two
different planes had to be evaluated in order to do so. The system should be steady and not
move in any direction, so the forces must cancel out. The reason for the use of roller bearings it
that it can simultaneously cope for large vertical and horizontal forces. The load capacity and
bearing life was determine to make sure that the bearing life will have exceed 20000 hours .
Bearing 1
Bearing 2
Bearing 3
Bearing 4
184.4
750
130
60
46
15
86800
27500
20000
100
184.4
750
130
60
46
15
86800
27500
20000
100
74.6
1500
110
50
40
15
64500
19800
20000
100
74.6
1500
120
55
43
15
75200
23500
20000
100
Bearing 3
25000
44.6
1.6
Bearing 4
25000
52.9
1.7
Bearing calculation
Bearing 1
25000
42.1
1.3
Bearing 2
25000
42.1
1.3