MECH 4650

Project #3: Reduction Gear Box for Small Fishing

Trawler

December 5, 2012

Prepared by

JORDAN KOERNER
Student Number: 7622734

LOGAN FRIDFINNSON
Student Number: 6855814

DEEPAK BALI
Student Number: 7619521

Prepared for

DR. URS WYSS

MECH 4650 – Machine Design 4M
Table of Contents
List of Figures ................................................................................................................................ iv

List of Tables ................................................................................................................................. iv

Executive Summary ........................................................................................................................ 1

1 Problem Statement .................................................................................................................... 2

2 Calculations for Designing Gear Box ....................................................................................... 3

2.1 Sizing Pinion and Gear ....................................................................................................... 3

2.1.1 Bending stress ........................................................................................................... 6

2.1.2 Pitting Resistance and Contact stress ........................................................................ 7

2.1.3 Pinion and Gear Characteristics ................................................................................ 9

2.2 Bearings Selection ............................................................................................................ 11

2.3 Design of Shaft ................................................................................................................. 13
3 Assembly Drawing.................................................................................................................. 18

4 Conclusions ............................................................................................................................. 19

References ..................................................................................................................................... 20

Appendix A: Engineering Drawings ............................................................................................. 21

List of Figures
Figure 1 - Gear box assembly of input shaft and bearings ........................................................... 18

List of Tables
Table I –Given data for input and gear ratio ................................................................................... 3

Table II - Optimal values after completion of the iterative process ............................................... 3

Table III - Bending stress factors .................................................................................................... 7

Table IV - constants used to calculate the pitting resistance .......................................................... 8

Table V - Variables used to calculate contact stress ....................................................................... 8

Table VI: Summary of bearings selected with key dimensions. ................................................... 13

Executive Summary
This engineering report, in its present form, considers the current situation in which a gearbox
for a main engine must be designed for a small fishing trawler. This report, examines helical
gear sizing, dimensioning of the input shaft where two critical locations on the input shaft are
highlighted, and the sizing of the bearings for the input shaft.

To determine the most feasible design for the given conditions, the process began by sizing the
helical gears. This process was completed through an optimization procedure to maximize the
factor of safety to a value greater than two. Once the gears were selected the tangential, radial,
and axial forces were calculated to determine the bearing loads and the stresses acting on the
shaft. After this, the bearings were sized where the number of revolutions was calculated to find
the equivalent dynamic bearing load for the design life. Finally, with the information obtained
from the gears and the bearings, the size of the shaft was calculated, and two critically stressed
areas were addressed. From this analysis, the most optimal design concept was selected, and was
refined to obtain a final design which would meet all the design requirements at hand. A final
sketch was created for the designed gear box.

It is evident from the analysis found in this report that the most optimal set of helical gears for
this application were gears having a helix angle of 15ᵒ, normal pressure angle of 20ᵒ and a face
width of 4.5in. The pinion has a pitch diameter of 4.8in and 28 teeth. The gear has a pitch
diameter of 21.7in with 126 teeth. Both the pinion and gear are made of AISI 4320 SOQT 300.
The bearings selected were single row, deep groove ball bearings. Bearing number 6330 and
6316 were used for the thrust and radial load bearing, respectively. Lastly, the shaft was designed
to have a diameter of D1= 3.94 inches, D2= 5.91 inches, D3= 8.86 inches, D4= 4.00 inches, and
D5= 3.15 inches, and the keyway was designed to have chordal height of 0.1 inches, the depth of
shaft keyseat of 3.27 inches, and the depth of the hub keyseat of 4.53 inches.

Page 1
1 Problem Statement
In many countries around the world, the use of small fishing trawlers has become a necessity due
to the amount of coastal and non-coastal fishing practices. There are a vast amount of
components to consider when designing fishing trawlers, but a critical component of the design
is the gear box. A gear box consists of three main components: the gears, bearings and the shaft.

The objective of this project is to design a gear box for a fishing trawler by appropriately sizing
the gears, bearings and shaft, provided the following design requirements:

 The gears must have a factor of safety greater than two for the bending stress and the
contact stress
 The two critical locations in the input shaft must have a factor of safety greater than two
 The bearing must be sized to accommodate the input shaft
 The gearbox must have a reduction of 4.5:1
 The gearbox must last twenty years while being used two hundred days in a year, and
twelve hours in a day

It is known that the gearbox for the small fishing has 235 horsepower supplied at 2000 RPM to
the input shaft, and is a non-reversible gearbox.

Page 2
2 Calculations for Designing Gear Box
This section will outline the necessary analytical procedure that is required in order to design our
reduction gear box. Calculations for sizing the gear will be done with respect to the bending and
contact stress, followed by a procedure to properly select bearings and lastly calculations were
done to determine an acceptable shaft size. All of the component will be designed using a factor
of safety of 2 or greater. All equations, figures and tables being used in this section were
acquired from our textbook [1].

2.1 Sizing Pinion and Gear

There are a multiple of gear sizes that can be considered an appropriate solution. Obtaining the
optimal pinion and gear sizing required going through an iterative process. Table I illustrates the
given variables of the input speed and power, as well as the velocity ratio.

Table I –Given data for input and gear ratio

Input power, P 235 hp

Input speed, np 2000 rpm
Velocity ratio, VR 4.5

There are five parameters under our control when sizing a gear or pinion, they are: helix angle,
Ψ, normal pressure angle, θn, quality number, Qv, normal diametral pitch, Pdn, number of pinion
teeth, Np and face width, F. After completing the iterative process the optimal values for these
parameters was obtained and can be seen in Table II.

Table II - Optimal values after completion of the iterative process

Helix angle, Ψ 15ᵒ

Normal pressure angle, θn 20ᵒ
Normal diametral pitch, Pdn 6
Number of pinion teeth, Np 28
Quality number, Q 10 (Table 9.2)

Page 3
A sample calculation, using the optimal values, of the analytical procedure used to size the
pinion and gear is outlined in below.

With the rotational speed of the pinion and velocity ratio, the rotational speed of gear was found
to be:

The number of teeth on the gear was found to be:

Transverse diametral pitch was found to be:

Transverse pressure angle was found to be:

( ) ( )

The axial pitch was calculated to be:

Page 4
In order to ensure true helical action, a face width of at least two axial pitches will be selected.
The nominal face width was found to be:

Face width is another parameter that can be adjusted to optimize our gear size. A face width of
4.5in will used as it is a more convenient value and it provides more desirable results in terms of
bending and contact stress.

The pinion pitch diameter was found to be:

The gear pitch diameter was found to be:

The pitch line velocity was calculated to be:

The three forces acting on the pinion tooth are tangential, axial and radial and are calculated to
be:

Page 5
Tangential force:

Axial force:

Radial force:

2.1.1 Bending stress

One of the main objectives is to size the pinion and gear to unsure a factor of safety greater than
2 with respect to the bending stress. In order to calculate the bending stress, multiple factors need
to be considered. A summary of the bending stress factors is shown in Table II.

Page 6
 Table III - Bending stress factors

Pinion geometry factor, Jp 0.48 (figure 9-17)

Gear geometry factor, Jg 0.45 (figure 9-17)

Overload factor, Ko 1.40 (figure 9-5)

Size factor, Ks 1.0 (figure 9-6)

Pinion proportion factor, Cpf 0.1119 (figure 9-18)

Mesh alignment factor, Cma 0.1959 (figure 9-19)

Load-Distribution factor, Km Km = 1.0 + Cpf + Cma = 1.31

Rim thickness factor, Kb 1.0 (figure 9-20)

Dynamic factor, Kv 1.2(figure 9-21)

The bending stress in the pinion was then found to be:

We are able to calculate the required Brinell hardness, HB using the following equation from
figure 9-10,

2.1.2 Pitting Resistance and Contact stress

Values required in order to calculate the pitting resistance are seen in Table IV - constants used
to calculate the pitting resistanceTable IV.

Page 7
 Table IV - constants used to calculate the pitting resistance

Elastic coefficient, Cp 2300 (figure 9-17)

Geometry factor for pitting 0.202 (figure 10-1)
resistance, I

The pitting resistance,

√ √

The gear box is to last 20 years when running 200 days a year, operating 12 hours per day. The
total service life is

The number of loading cycles,

In order to calculate the contact stress we need certain variables. These variables are summarized
in Table V.

Table V - Variables used to calculate contact stress

Reliability factor, KR 1.25 (Table 9.8 with reliability of

99.9%
Stress cycle factor, Zn 0.85 (figure 9-24)
CH 1.0
Factor of safety, SF 2 (Required)

The contact stress is found to be,

Page 8
From table 9-3, we find that for , a grade 3 carburized and case-hardened with
a hardness at the surface to be 58-64 HRC is recommended.

A suitable material was then selected from Appendix 5; keeping in mind that the required surface
hardness should be 58-64 HRC and the Brinell hardness of at least 136.4 HB. This Brinell
hardness is double the required hardness to account for a factor of safety greater than 2. The
material selected to satisfy these conditions was AISI 4320 SOQT 300, which has a case
hardness of 62 HRC and a Brinell hardness 429 HB.

2.1.3 Pinion and Gear Characteristics

The final characteristics of the pinion and gear are found below.

Addendum,

Dedendum,

Clearance,

Tooth Thickness,

Working depth,

Page 9
Whole depth,

Root Diameter Pinion,

Base Diameter Pinion,

Outside Diameter Pinion,

Root Diameter Gear,

Base Diameter Gear,

Outside Diameter Gear,

Page 10
2.2 Bearings Selection
Since the helix angle of the gears is small (15°), we can assume that single row, deep groove ball
bearing will be sufficient to handle the thrust forces.

The load/life relationship for rolling contact bearings can be stated as:

( )

This can be rearranged for solve for the basic dynamic load rating, C:

( )

Where Ld is the equivalent revolutions required in a lifetime. The engine operates at 2000 rpm,
12 hours per day, 200 days per year, with a design life of 20 years. The total design lifetime, in
minutes is:

Therefore, we can now find the revolutions per lifetime:

( )

The thrust bearing is chosen using the following analysis. Assume Y = 1.50, then:

Where V is the rotation factor (V = 1.0 for rotating inner race), X is the radial factor (assumed to
be X = 0.56 for all values of Y), R is the radial load, T is the thrust load, and Y is the thrust
factor. Using these values, we obtain P = 1879.04 lb. Using the equation for basic dynamic load
rating stated above and assuming k = 3 for ball bearings, we find:

Page 11
From Table 14-3 [1], we can see that bearing number 6322 has a basic dynamic load rating of
35,500 lb, with Co = 38,000 lb. Following the analysis shown in example problem 14-4 [1], with
T/R > e, we find that:

This yields new equivalent load and basic dynamic load rating values of:

Since Cnew > C, bearing number 6322 is not satisfactory for this application. The process is
repeated for bearing number 6330. This bearing has a basic dynamic load rating of C = 47,500
lb, and a basic static load rating of Co = 58,000 lb. Following the analysis shown in example
problem 14-4 [1], we find:

This yields:

This basic dynamic load rating is lower than that stated for bearing number 6330, therefore this
bearing will suffice.

For the bearing handling radial forces only, it was again assumed that the rotational factor, V =
1.0. Our equivalent load is found as:

This yields a basic dynamic load rating of:

A bearing was selected by choosing an appropriate size of bore for the driveshaft. Bearing
number 6316 was found to satisfy the dimensional and basic dynamic load rating requirements.

Page 12
 Table VI: Summary of bearings selected with key dimensions.

Bearing Number 6330 6316

Outer Diameter, D (in) 12.5984 6.6929
Bore, d (in) 5.9055 3.1496
Thickness, B (in) 2.5591 1.5354

2.3 Design of Shaft

The design of a shaft is a crucial component of the gearbox. Dependent on the size of the gears
and the bearings, the shaft diameters are determined. However, the diameters cannot be just
obtained from the gears and the bearings, as a minimum shaft diameter is required for each
section of the shaft. Thus, using the following technique, the minimum required shaft diameter
was determined. Based on this, the actual diameters of the shaft are determined.

The picture below depicts the shaft size, and the different diameters within the shaft,

A B C
15” 10”

r2
r1 r3 r4

D1
D3 D4 D5
D2

r1 and r4 = well rounded fillets

r2 and r3 = sharp fillets

Page 13
To determine the minimum required diameters for the shaft, the torque transmitted on the shaft
was calculated from the power provided of 235 HP and a rotation speed of the shaft of 2000 rpm.

( ) ( )

The forces exerted on the shaft were found for the gear,

From this, a FBD was created for the radial and tangential forces acting on the shaft,

Wt Wr
3065.63 lb 115.16 lb

15 10 15 10

R1t R2t R1r R2r

The reaction forces, R1 and R2 (forces counteracting from the bearings), are calculated as follows
for both the tangential forces,

Σ𝐹𝑦 Σ𝐹𝑦

𝑅 𝑡 𝑅 𝑡 𝑅 𝑟 𝑅 𝑟

Σ𝑀𝐴 Σ𝑀𝐴

𝑅 𝑡 𝑅 𝑡

𝑅 𝑡 𝑙𝑏 𝑅 𝑟 𝑙𝑏

𝑅 𝑡 𝑙𝑏 𝑅 𝑟 𝑙𝑏 Page 14
 From this, the shear stress, and bending moment diagrams are drawn as follows,

1226.25 lb 46.06 lb

-69.10
-1839.75 lb

18393.75 lb 690.96 lb

Next, we must select our material for the shaft that has good ductility with a percent elongation
above 12%. The material selected is AISI 1144 OQT 1000 steel, with the following properties

As an estimate, Cs= 0.75 and CR=0.81 (reliability of 0.99). We are now able to calculate
estimated actual endurance.

We are now able to calculate the minimum diameters are each point,

Page 15
Point A:

[ √[ ] [ ] ]

Since N=2, M=0, the diameter is calculated as,

[ √[ ] [ ] ]

Point B:

The bending moment at point B must be calculate using,

√ √

where kt=2.0 (profile keyseat),

[ √[ ] [ ] ]

We must apply a ring groove factor of 1.06, the minimum diameter now becomes,

Point C:

At point C, the seat for the second bearing, no torque or bending moment is applied. However,
there is a vertical shearing force equal to the reaction force (of the bearing). The shearing force
can be calculated as,

And the minimum diameter as,

Page 16
 √ √

The diameter D1, is slightly smaller than D2 and D3 is slightly larger than D4 to provide adequate
shoulders for the gear at B, and the bearing A.

As the gear and the bearing sizes have been determined, the shaft must accommodate those
dimensions. Thus, the diameters are calculated to be:

D1= 3.94 inches

D2= 5.91 inches

D3= 8.86 inches

D4= 4.00 inches

D5= 3.15 inches

Next, the keyway was designed for the chordal height, the depth of shaft keyseat, and the depth
of the hub keyseat.

To calculate the chordal height,

√ √

To calculate the depth of the shaft keyseat,

√ √

To calculate the hub keyseat,

√ √

Page 17
3 Assembly Drawing
The completed assembly including the input shaft, the radial load bearing and the thrust load
bearing. The pinion is not shown, however its location and the direction of rotation are illustrated
in Figure 1.

Figure 1 - Gear box assembly of input shaft and bearings

Fully dimensioned drawing can be found in Appendix A.

Page 18
4 Conclusions
In conclusion, a 4.5:1 reduction gear box, using helical gears, with a lifespan of 20 years was
required for a small fishing trawler. The gear box consists of 3 main components; the pinion and
gear, the shaft and the bearings. First, the pinion and gear were sized using an iterative process.
A helix angle of 15ᵒ, normal pressure angle of 20ᵒ, normal diametral pitch of 6 and face width of
4.5in were found to be the optimal values after completing the iterative process. The pinion has a
pitch diameter of 4.8in and 28 teeth. The gear has a pitch diameter of 21.7in with 126 teeth. Both
the pinion and gear are made of AISI 4320 SOQT 300.

Next, the bearings were selected to satisfy the lifespan as well as axial and radial forces from the
gears. It is recommended that a single row, deep groove ball bearing be used. Bearing number
6330 for the thrust bearing and bearing number 6316 for the radial load bearing were used.

Lastly, the shaft was designed to have a diameter of D1= 3.94 inches, D2= 5.91 inches, D3= 8.86
inches, D4= 4.00 inches, and D5= 3.15 inches, and the keyway was designed to have chordal
height of 0.1 inches, the depth of shaft keyseat of 3.27 inches, and the depth of the hub keyseat
of 4.53 inches. All requirements of the design project were satisfied, and a factor of safety of 2
were met.

Page 19
References
[1] R. Mott, Machine Elements in Mechanical Design, 4th ed. Upper Saddle River, NJ: Pearson
Education, Inc, 2004

Page 20
Appendix A: Engineering Drawings

Page 21
Page 1
Page 2