Design Procedure of Gear Box for Automobile and Machine Tools

8/28/2015

Desi gn pr ocedur e of Gear Box for automobi l e and m achi ne tool s

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Design procedure of Gear Box Box for automobile and machine tools Updated: 20‐

Category: Mechanical

May‐2015

Projects

Author: Paresh

Member

Gujarati

Level: Gold

Points:: 60 Points

This This resource gives gives complete design of Gear Box. This This includes step step by step guide to design of each compone components nts of Gear Gear Box. These include gear design,

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shaft design, casing design as well as other

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important parts of Gear Box. Read the complete

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article to get the details.

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http://www. www.in ind diast iastu udych ychannel.co l.com/ m/re reso sou urce rces/1 s/156770-Desi -Desig gn-Pro -Proce ced dure-G re-Ge ear-Bo r-Box-A x-Automob mobile-Ma ile-Mach chin ine e-Too -Tools. ls.aspx spx

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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

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transmission device according to the requirements of

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torque. We normally use various power transmission devices like lathe machine, drilling machine, milling machine or any other machine tools which require

R Pramod 134 Ank Arya 108 M. K. 83

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

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R Pramod 1095 M. K. 756 Naveen 744

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

Jyoti Nagargoje

different torque or power and thus, we can fulfil the

Zeba

requirements by changing the speed. This speed

Vandana

variation can be done by using different gear having

Seema Mittal

different teeth cut on it on various shafts at proper

Nidhi

distance to have perfect mesh in between the two

Sheo Shankar Jha

gears. In case of lathes, milling machines the speeds

Jebaprincy

are fixed by the required cutting feed and/or cutting

Kailash Kumar

speed for a range of materials. Low strength materials

Jagdish Patro

can be cut at higher speed and high strength material

suparnee

required higher torques so that speed needed is very

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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 http://www.indiastudychannel.com/resources/156770-Design-Procedure-Gear-Box-Automobile-Machine-Tools.aspx

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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 http://www.indiastudychannel.com/resources/156770-Design-Procedure-Gear-Box-Automobile-Machine-Tools.aspx

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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 http://www.indiastudychannel.com/resources/156770-Design-Procedure-Gear-Box-Automobile-Machine-Tools.aspx

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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 http://www.indiastudychannel.com/resources/156770-Design-Procedure-Gear-Box-Automobile-Machine-Tools.aspx

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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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Design Procedure of Gear Box for Automobile and Machine Tools

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