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.

Reduction gearbox design description

The design was made to accommodate a power transfer of 30kw at a drive speed of 1500 rpm
and the gearbox is to reduce the speed to 750 rpm. The design was made to give an overall
efficiency of 95% and it has a life span of approximately twenty thousand hours.

The parameters of for each gear

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

Diameter gear (mm)

142.035

275.418

Mass of gear (Kg)

4.478

25.753

Pressure angle (deg.)

20

20

The single stage reduction gearbox

The single-stage spur gear unit we are considering in this work is highly standardized, both in
terms of its layout and in terms of design of its gearings, shafts, radial sealing and tapered roller
bearings. The set of genes that define the single-stage spur gear unit unequivocally reflects this,
with standardization imposing discrete values sets on most of them. The problem of minimum
mass design of simple and multi-stage spur gear trains has been a subject of considerable
interest, since many high-performance power transmission applications (e.g. automotive,
aerospace, machine tools, etc.) require low mass. For this reason, in this study, minimization of
single-stage spur gear unit mass is the objective function. This system consists of two gears
supported by a two shaft. The bearings, the gears, the shaft, and the keys need to be designed
and analyzed. The first components analyzed were the gears. The reason behind this is that
theres more information from which to attain, and this speeds up the design process.

Results of test and calculations

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%.

Tangential force (N)

Radial force (N)
Axial force (N)
Normal force (N)
Velocity (m/s)
Factor of safety form pitting
Factor of safety from tooth breakage
Torque (Nm)

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.

Length of shaft (mm)

Mass of shaft (Kg)
Maximal bending stress(MPa)
Maximal shear stress(MPa)
Maximal reduce stress(MPa)
Maximal Defection (m)
Torque (Nm)

Shaft 1 (Pinion Shaft)

391
10.74
0.274
0.023
0.275
0.236
191

Shaft 2 (Gear Shaft)

388
11.85
0.166
0.02
0.166
0.15
374

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 properties and parameters

Properties and parameters

Bearing 1

Bearing 2

Bearing 3

Bearing 4

Radial load (N)

Speed (RPM)
Outside diameter(mm)
Inside diameter(mm)
Bearing width(mm)
Contact angle (Deg.)
Basic dynamic load rating (N)
Static loading(N)
Require life (Hrs.)
Max Working temperature(C)

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

Rating life (Hrs.)

Static safety factor
Frictional loss (W)

Bearing 1
25000
42.1
1.3

Bearing 2
25000
42.1
1.3

Conclusion and recommendation

The critical features involved in the design of the gear reduction system have been determined
through the use of statics, strength, and fatigue analyses. The calculation of the safety factor
under various conditions and loadings has made it clear that the system will not fail. The gears
have very large safety factors under bending, which indicates that our selection of materials is
extremely safe and conservative. For wear, the safety factor was smaller, on the average safety
factor range, indicating that our selection is good. The bearings were carefully decided upon to
be very safe as well, and to withstand the loads to which the system is subjected. The shaft is
made of a very strong material that can withstand a lot of fatigue and stress. The determination
of our safety factor under fatigue proves that the shaft will not fail and our selection is good.
For static and tensile loading, our shaft is very strong, and the safety factors were big, meaning
that our selection is safe and conservative. During the analysis of this system, one of the most
important things that were considered was the reliability.