ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I Vol-03, Issue-06, June 2015

Adaptive Design of Machine Tool Gearboxes

Dr M. A. Asy
mohamedasy2010@yahoo.com
Department of Production Engineering & Mech. Design
University of Menoufia
Shebin El-Kom, Menoufia, Egypt

Abstract boxes [1-13]. Structural formulae, structural diagrams, and ray

This paper aims to design multi speed minimum size gearboxes. diagrams i.e. speed charts were constructed and a design
Simplification in gear meshing location and double speed electric procedure is carried out in details for 4 and 6 speed gearboxes.
motors are proposed to achieve this goal. Simplified gear meshing The number of teeth for all gears, deviation between
location is the use of one or more driven gears on the intermediate
theoretical and actual speeds is estimated as given in
shaft as driver gears for the last shaft. Keeping the machine tool
gearbox speeds in geometrical progression is the most important references [7& 13]. From the previous studies, it is clear that
constrain. Two case studies are considered; four and there is a shortage of the published material in the field of
six speeds gearboxes with three shafts. A comparative study for machine tool multi-speed gearboxes design. Very limited
the two gearboxes is made in case of conventional structure and attention was paid on those which have simplified meshing
two simplified meshing locations. The minimum number of teeth locations and driven by single and/or double speed electric
and the actual speeds are calculated according to the speed chart motors. In this paper, two stages (three shafts) four and six
construction, considering one of the standard progression ratios speed gearboxes driven by double speed electric motor are
and compared with the theoretical speeds. The obtained actual considered. A comparative study for the two gearboxes is made
speeds are in a geometric progression and the deviation between
in the case of conventional structure and two simplified
theoretical and actual speeds are in the permissible limits. Saving
ratio in gears and gear utilization factor in 4, 6, 8, and 9 speed meshing locations. The minimum number of teeth and the
gearboxes are calculated. Reducing the number of gears in actual speeds under specified standard progression ratios are
gearbox with two simplified meshing positions has positive effect calculated based on the speed chart. The actual speeds are
on the gearbox dimensions and consequently reducing the overall compared with the theoretical speeds. The obtained actual
cost. The maximization of gear utilization factor is made by speeds are in a geometric progression. The deviation between
driving these gearboxes with double speed electric motors theoretical and actual speeds are in the permissible limits.
which doubles the number of speeds produced when using single Saving ratio in gears and gear utilization factor in 4, 6, 8, and 9
speed electric motors are used. speed gearboxes were calculated. Reducing the number of gears
in gearbox with two simplified meshing positions has positive
1. Introduction: effect on the gearbox dimensions and consequently reducing
the overall cost. The maximization of gear utilization factor is
In designing gear drives, reliability of operation, efficiency, achieved by using double speed electric motors. Actually,
service life, load carrying capacity and overall cost are double speed motors add two speed, one stage reduction.
considered. Efficiency of gear drives significantly depends on
the frictional losses during the operation especially in low 2. Design Procedure:
efficiency gear drives. Overall cost includes manufacturing,
running and maintenance. Gears have many advantages that Design of gearboxes with two simplified meshing locations
makes them vital power transmitting elements in any involves two case studies; four and six speeds. The procedure
mechanical system. The primary objective of the application contains the construction of a kinematic diagram, number of
of gear drive is to transmit the power between mating gears teeth calculations, calculations of actual speeds, and error
at constant velocity ratio, which is essential in machine tools. between actual and theoretical speeds. Moreover, error between
Designers of multipurpose machine tools had to provide a actual and theoretical speeds are compared with the permissible
certain speed range which covers the requirements of different error limits.
operations, types and shapes of work pieces and qualities of the
surfaces that are to be machined. Values of the required cutting Case (1):
speeds depend upon technical and economic considerations. Four Speed Gearbox
Greater variety of materials used for tools and work piece, the The kinematic diagram of conventional gearbox delivers 4
wider speed range is required for the cutting speed range. speeds has the structural diagram shown in Fig. (1-a).
Several references enhanced the design of gears and/or gear

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 ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I Vol-03, Issue-06, June 2015

b is the distance between the second and third shafts in the

gearbox.

a= (mZ3/2+ mZ4/2) = (mZ4/2)* (Z3/Z4 +1) = (mZ4/2)/ (i2+1)

(5)
b= (mZ5/2+ mZ6/2) = (mZ5/2)* (1+Z6/Z5)= (mZ5/2)/ (1+1/i3)
(6)
a/b = (i2+ 1)/(1+1/i3) = (i2i3+i3)/(i3+1) (7)

Also,
a b a= (mZ1/2 + mZ2/2) = (mZ2/2)/ (i1+1) (8)
Fig. (1) Kinematic Diagram of 4 Speed Gearboxes: b= (mZ7/2 + mZ8/2) = (mZ7/2)/ (1+1/i4) (9)
a- Conventional b- Two Simplified Meshing locations. a/b = (i1+ 1)/ (1+1/i4) = (i1i4+i4)/ (i4+1) (10)

Actual Speed Equations: From Eqs. (7) and (10)

(i2i3+i3)/ (i3+1) = (i1i4+i4)/ (i4+1)
N1 = N * Z1/Z2 *Z5/Z6 = N*i1*i3 From equation (3) substitute into equation (4)
N2 = N * Z1/Z2 *Z7/Z8 = N*i1*i4 (io/f2 +f * i4)/ (f * i4+1) = (io/f + i4)/ (i4+1)
N3 = N * Z3/Z4 *Z5/Z6 = N*i2*i3 (1) i4(io+ f3 – f2io – f2) = io(f-1) (11)
N4 = N * Z3/Z4 *Z7/Z8 = N*i2*i4 i4 = [io* (f-1)/ [(f-1)*{f2 – io * (f+1)}]
Where: i4 = io/ [f2 – io * (f+1)] (12)
N = the input speed on the first shaft in the gearbox.
N1= highest speed at the gearbox spindle rpm Assume:
N4 = lowest speed at the gear box spindle rpm A = [f2 – io * (f+1)] (13)
i1, i2, i3 and i5 = the transmission ratios for Z1/Z2, Z3/Z4, Z5/Z6 i4 = io / A (14)
and Z7/ Z8 respectively According to equation (3)
Assume: i3 = i4 * f
N1/N = io (2) i3 = io * f/ A (15)
i1* i3 = N1/N= io i2 * i3 = io /f
i1* i4 = N2/N= N1/ (N*f) = io/ f i2 = A/f3 (16)
i2* i3 = N3/N= N1/ (N*f2) = io/ f2 (3) i1 = A/ f
i2* i4 = N4/N= N1/ (N*f3) = io/ f2
Where: According to Fig. (2)
io = the ratio between the highest speed on the gearbox spindle Z1/ Z8 = Z1/ Z2 * Z7/Z8 = i1 * i4 = io/f
to the input speed on the first shaft. Z3/ Z6 = Z3/ Z4 * Z5/Z6 = i2 * i3 = io /f2
f = the base of progression transmission ratio
From equation (3): It is clear that the small transmission ratio is io /f2. Therefore, it
i3/ i4 = f must calculate the limits for this value in the case of using the
i1/ i2 = f2 (4) simplified meshing position gearbox.
For the gearbox shown in Fig. (1-a) If two simplified meshing Also, the lowest transmission ratio is i2 = A/f3 which must be
locations are made the kinematic diagram will be as shown in ≥ 1/4 (17)
Fig. (1-b). If the progression ratio is f = 2.0
The gearbox in simplified locations form has two gears io/ f = io/4 ≥ 1/4 (18)
working as driven and drivers according the path of power and io = 1.0
the engagement mechanism. Because these two gears working A = [f2 – io * (f+1)] = 1.0 (19)
as idler gears, they have the same specifications i.e. number of i2= A/f3 = 1/8
teeth, module and dimensions i.e. Z2 = Z7 and Z5 = Z6. To If io > 1 then i2 <1/8
achieve this condition a special treatment should be followed This means io must be less than unity, also Z3/Z6 must be less
through the following design procedure. than 1/4.
Assume: It is clear that the best condition for this case is when i2 =
a is the distance between the first and second shafts in the Z3/Z6;
gearbox. Z3/Z6 = i2 * i3 = i2 (20)
This means i3 = 1.0

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 ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I Vol-03, Issue-06, June 2015

i3 = io* f /A = 1.0 (21) CI= 82 teeth

A = io *f Where CI is the summation of teeth for pair gears between the
Also, A = [f2 – io * (f+1)] first and second shafts.
A = [f2 – io * (f+1)] = io* f (22) Z3 = 26*82/126 = 17 teeth
f2 = 2*io* f + io Z4 = 100* 82/126 = 65 teeth
io = f2/ (2*f+1) (23) Z1 = 52* 82/152 = 28 teeth
Equation (23) represents the general equation to design the Z2= 100*82/152=54 teeth
gearboxes with Simplified meshing locations
For Stage II
Table (1) the Relation between the Suitable Transmission Ratios
(The transmission ratios between the second and third shafts).
and Progression Ratio for Gearboxes Deliver 4 speeds and has
Two Simplified Meshing Locations [8]. Table (3) Conversion of Transmission Ratio Fraction into Form
symbol Value of Numerator and Denominator.
ij ii= fi/ gi (fi+ gi)
f 1.06 1.12 1.26 1.41 1.58 2 ij = Zi/ Zj+1 Zi/ Zi+1 (Zi+ Zi+1)
io 0.36 0.39 0.45 0.525 0.6 0.8 i3 = Z5/Z6 1 2
i4 =Z7/Z8 715/1000 1715
A 0.38 0.435 0.56 0.735 0.95 1.6
i1 0.36 0.39 0.442 0.52 0.595 0.8
i2 0.322 0.309 0.28 0.26 0.237 0.2
The maximum power involves the minimum size gear
i3 1 1 1 1 1 1
Z5 = Z6 = Z4 = 65 teeth
i4 0.944 0.89 0.792 0.715 0.623 0.5 CII= Z5 + Z6 =130 teeth
Where CII is the summation of teeth for pair gears between the
According to kinematic diagram shown in Fig. (1-b) and Table second and third shafts.
(1): Z7+ Z8 =130 teeth
The Design procedure For 4 speed gearbox with two Z2= Z7 = 54 teeth
simplified meshing locations: Z8 = 130- 54 = 76 teeth
Take f= 1.41
Table (4) Number of Teeth for all Gears.
io = 0.526
Gear No. Z1 Z2-7 Z3 Z4-5 Z6 Z8
i1= Z1/Z2=0.52 No. of Teeth 28 54 17 65 65 76
i3= Z3/Z4= 0.26
i3= Z5/Z6= 1
i4= Z7/Z8 = 0.715
No. of teeth calculations:
For Stage I (The transmission ratios between the first and
second shafts).

Table (2) Conversion of Transmission Ratio Fraction into Form

of Numerator and Denominator.
ij ii= fi/ gi (fi+ gi)
ij = Zi/Zj+1 Zi/Zi+1 Zi/Zi+1
i1 = Z1/Z2 52/100 152
i2 = Z3/Z4 26/100 126
Figure (2) Speed Chart for 4 Speeds Gearbox with Two
Where: Simplified Meshing Locations.
fi= The number of teeth for the driver gear
gi= The number of teeth for the driven gear Actual Speed Calculations: The system is driven by single
The maximum power involves the minimum size gear speed electric motor
Assuming constant module for all gears in stage I. N1= N* Z1/Z2-7 * Z4-5/Z6 = 1000 * 28/54 * 65/65 = 518 rpm
The summation of teeth for each pair in stage I i.e. C I, can be N2 = N* Z1/Z2-7 * Z2-7/Z8 = 1000 * 28/54 * 54/76 = 369 rpm
calculated as follows: N3 = N* Z3/Z4-5 * Z4-5 /Z6 = 1000 * 17/65 * 65/65 = 261 rpm
Assuming the min. available No. of teeth can be used in the N4 = N* Z3/ Z4-5 * Z2-7 /Z8 = 1000 * 17/65 * 54/76 = 185 rpm
gearbox= 17 teeth
CI* fi/ (fi+ gi) = min. no. Of teeth= 17
CI* 26/126= 17

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 ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I Vol-03, Issue-06, June 2015

Table (5) Theoretical, Actual Speeds and Speed Deviation.

Table (6) Shows the Relation between the Suitable Transmission
Ratios and Progression Ratio for Gearboxes Deliver 6 speeds and
has Two Simplified Meshing Locations [8].
symbol Value
f 1.06 1.12 1.26 1.41 1.58 2
io 0.565 0.647 0.835 1.06 1.365 2.18
Case (2):
Six Speeds Gearbox: B 0.63 0.82 1.22 2.13 3.4 8.65
The kinematic diagram of conventional gearbox delivers 6 i1 0.56 0.65 0.834 0.06 1.36 2.16
speeds has the form shown in Fig. (3-b). i2 0.475 0.46 0.417 0.385 0.34 0.27
i3 1 1 1 1 1 1
i4 0.934 0.89 0.716 0.71 0.633 0.5
I5 0.89 0.79 0.63 0.5 0.4 0.25

For the gearbox shown in Fig. (3), if two simplified meshing

locations are made, the kinematic diagram will be constructed.
The gearbox has two options to construct speed chart of the
gearbox. The two options are shown in Fig. (4), considering
f=1.26.

From the two options of speed chart the best is the first one,
a b which has the lowest number of nods. (Summation number of
Figure (3) Kinematic Diagram for 6 Speed Gearboxes: intersection points in speed chart between the vertical lines
a- Conventional b- Two Simplified Meshing Locations. represent the shafts and the horizontal lines represent the speeds
calculated from the upper to the lowest point represent speed on
Actual Speed Equations: each shaft) [7]. Therefore, the first option will be taken in
N1 = N* Z1/ Z2* Z5/ Z6 = N* i1* i3 consideration for design calculations of the gearbox.
N2 = N* Z1/ Z2* Z7/ Z8 = N* i1* i4
N3 = N* Z1/ Z2* Z9/ Z10= N* i1* i5
N4= N* Z3/ Z4 * Z5/ Z6 = N* i2* i3 (24)
N5 = N* Z3/ Z4 * Z7/ Z8 = N* i2* i4
N6 = N* Z3/ Z4 *Z9/ Z10 = N* i2* i5
Where:
N = the input speed on the first shaft in the gearbox.
N1= highest speed at the gearbox spindle rpm
N6 = lowest speed at the gear box spindle rpm
i1, i2, i3, i4 and i5 = the transmission ratios for Z1/Z2 , Z3/Z4 ,
Z5/Z6 , Z7/Z8 and Z9/Z10 respectively
Assume: Option (1) Summation of Option (2) Summation of
N1 / N = i O (25) Nods = 1+ 6 +7 = 14 Nods = 2+ 6 +7 = 15
i1* i3= N1/ N= io (a) (b)
i1* i4= N2/ N= N1/ (N* f) = io/ f Figure (4) Speed Charts for 6 Speeds Gearbox with Two
i1* i5= N3/ N= N1/ (N* f2) = io/ f2 (26) Simplified Meshing Locations for Single Speed Motor.
i2* i3= N4/N= N1/(N*f3) = io/ f3
i2* i4= N5/N= N1/(N*f4) io/ f4 According to the kinematic diagram the following equations
Where: can be derived:
io = the ratio between the highest speed on the gearbox spindle a= (m* Z3/ 2 + m* Z4/ 2) = (m*Z4/ 2)/ (i2+ 1) (28)
to the input speed on the first shaft. b= (m* Z5/ 2 + m* Z6/ 2) = (m* Z5/ 2)/ (1+ 1/i3) (29)
f = the base of progression transmission ratio a/ b = (i2+ 1)/ (1+1/ i3) = (i2* i3+ i3)/ (i3+1) (30)
From equation (3) Also,
i3/ i5 = f2 a= (m* Z1/ 2 + m* Z2/ 2) = (m* Z2/ 2)/ (i1+ 1) (31)
i3/ i4 = i4/ i5 = f (27) b= (m* Z9/ 2 + m* Z10/ 2) = (m* Z9/ 2)/ (1+1/ i5) (32)

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a/b = (i1+ 1)/ (1+1/ i5) = (i1* i5+ i5)/ (i5+1) (33) CI = 17* (Z3+ Z4)/ Z3
CI = 17* (52+ 125)/ 52 = 58 teeth
From equations (3) & (6): Z1= CI* f1/ (f1+g1) i.e.
(i2* i3+ i3)/ (i3+1) = (i1* i5+ i5)/ (i5+1) (34) Z1= 58 *831/1831 = 26 teeth
i1* i3= io Z2= CI* g1/ (f1+g1) i.e.
i1* i4= io/ f Z2 = 32 teeth
i1* i5= io/ f2 Similarly:
i2* i3= Io/ f3 Z3 = 58 * 52/177 = 17 teeth
i2* i4= io/ f4 (35) Z4 = 41 teeth
i2* i5= io/ f5
i1/ i2= f3 Stage II:
i3/ i4= i4/ i5= f Z2= Z9= 32 teeth
i3/ i5 = f2 Z4= Z5= Z6= 41 teeth
i5* [f3* (f+1)– io* (f2+ f+1)] =io (36) CII = Z5+ Z6= 82 teeth
Let f3* (f+1)- io* (f2+ f+ 1)= B=1.32 (37) i4= Z7/Z8* 0.79
i5= io/ B= 0.63 Z7= 0.79* Z8
i3=i5* f2= io* f2/ B= 0.1 Z7+ Z8= 82 teeth
i4= i3/ f = io* f2/ (B* f) = io* f / B = 0.79 (38) Z8= 46 teeth
i2= io / (f5* i5) = B/ f5= 0.416 Z7= 36 teeth
i1= io / i3= B/ f2= 0.831 i5= 0.63 = Z9/ Z10= 32/Z10
Z9= Z2= 32 teeth
io Calculation: Z10= 50 teeth
Z3/ Z6= Z3/ Z4* Z5/ Z6 = i2* i3 = io / f3 (39) i1= io/ i3 =B/ f2= 0.831
Z1/ Z10= Z1/ Z2* Z9/ Z10 = i1* i5 = io/ f2 (40) i2= io/ (f5*i5) = B/ f5 = 0.416
Notice that i2 is the minimum reduction ratio i3= i5* f2 = io* f2/B = 1.0
i2* i3= i2 (41) i4= i3/ f = io* f/ B = 0.79
i3= 0.1 (42) i5* io/ B = 0.63
io* f2/B= 1 (43)
io* f2= B = f3* (f+1) – io* (f2+ f+ 1) (44) N1= Nm* Z1/ Z2-9* Z5/ Z6 = 1000* 0.81 = 810 rpm
io = f3* (f+1)/ (2* f2+f+1) = 0.832 (45) N2= Nm* Z1/ Z2-9* Z7/ Z8 = 1000* 0.64 = 640 rpm
N3 = Nm* Z1/ Z2-9* Z2-9 / Z10 = 1000* 0.52 = 520 rpm
Number of Teeth Calculations: N4= Nm* Z3/ Z4-5* Z4-5/ Z6 = 1000* 0.41 = 410 rpm
Stage I: N5 = Nm* Z3/ Z4-5* Z7/ Z8 = 1000* 0.32 = 320 rpm
According to equation (45) and speed chart shown in Fig. (4), N6 = Nm* Z3/ Z4-5* Z2-9/ Z10 = 1000* 0.26 = 260 rpm
the following table can be constructed.
Table (8) Theoretical, Actual Speeds and Speed Deviation for Six
Table (7) Conversion of Transmission Ratio Fraction into Form Speeds Gearbox Driven by Single Speed Electric Motor.
of Numerator and Denominator.
ij ii= fi/ gi (fi+ gi)
i1= Z1/Z2 831/ 1000 1831
i2= Z3/Z4 0.416 = 52/ 125 177

The maximum power involves the minimum size gear

Assuming constant module for all gears in stage I.
The summation of teeth for each pair in stage I i.e. C I, can be
calculated as follows:
Assuming the min. available No. of teeth can be used in the Similarly the same sequence can be followed to construct
gearbox= 17 teeth gearboxes to give 8 and 9 speeds with two simplified meshing
- Determine the lowest transmission ratio in stage I i. e. i2 = Locations.
52/125
- The driver gear for the lowest transmission ratio known as
Zmin.
- In this case i2= Z3/ Z4; Z3 = Zmin.
CI* Z3/ (Z3+ Z4) = 17

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Using Double Speed Electric Motor to Drive Gearboxes with

Two Simplified Meshing Locations

For the gearbox shown in Fig. (1-b). assume the ratio between
the high and low speeds of electric motor Um equals:
Um = 3000/750 = 4

Fig. (6) Speed Chart for 12 Speeds Gearbox with Two Simplified
Meshing Locations Driven by Double Speed Electric Motor.

N1= Nmh* Z1/ Z2* Z5/ Z6= 3000* 0.81= 2430 rpm
N2= Nmh* Z1/Z2* Z7/ Z8= 3000* 0.64= 1920 rpm
N3= Nmh* Z1/Z2* Z9/ Z10= 3000* 0.52= 1560 rpm
Fig. (5) Speed Chart for 8 Speeds Gearbox with Two Simplified
Meshing Locations Driven by Double Speeds Electric Motor. N4= Nmh* Z3/Z4* Z5/ Z6 = 3000* 0.41= 1230 rpm
N5 = Nmh* Z3/Z4* Z7/ Z8= 3000* 0.32= 960 rpm
Actual Speed Calculations: N6= Nmh* Z3/Z4* Z9/ Z10= 3000* 0.26= 780 rpm
N7 = Nml* Z1/Z2* Z5/ Z6 = 750* 0.81= 607.5 rpm
N1= Nmh* Z1/ Z2-7* Z4-5/Z6 = 1000* 0.81 = 518 rpm N8 = Nml* Z1/Z2* Z7/ Z8= 750* 0.64= 480 rpm
N2= Nmh* Z1/ Z2-7* Z2-7 /Z8 = 1000* 0.64 = 369 rpm N9= Nml* Z1/Z2* Z9/ Z10= 750* 0.52= 39 rpm
N3 = Nmh* Z3/ Z4* Z4-5/Z6 = 1000* 0.52 = 261 rpm N10= Nml* Z3/Z4* Z5/ Z6= 750* 0.41= 307.5 rpm
N4= Nmh* Z3/ Z4-5* Z2-7/Z8 = 1000* 0.41 = 185 rpm N11= Nml* Z3/Z4* Z7/ Z8= 750* 0.32= 240 rpm
N5 = Nml* Z1/ Z2-7* Z4-5/Z6 = 500* 0.32 = 129.5 rpm N12= Nml* Z3/Z4* Z9/ Z10= 750* 0.26= 195 rpm
N6 = Nml* Z1/ Z2-7* Z2-7/Z8 = 500* 0.26 = 92.25 rpm Where:
N7= Nml* Z3/ Z4-5* Z4-5/Z6 = 500* 0.81 = 65.25 rpm Nmh = High speed of the electric motor rpm
N8= Nml* Z3/ Z4-5* Z2-7/Z8 = 500* 0.64 = 46.25 rpm Nml = Low speed of the electric motor rpm

Table (9) Theoretical, Actual Speeds and Speed Deviation for 8 Figures (7& 8) summarize the different cases of kinematic
Speeds Gearbox Driven by Double Speed Electric Motor. diagrams, speed charts and improvement occurs on the gearbox
shape when two simplified locations and using single or double
speed electric motor to produce 8& 12 speeds respectively.

For the gearbox shown in Fig. (4-b) when it is derived by

double speed electric motor, the speed chart will be as shown
in Fig. (6).

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3. Results and Discussions:

The present study clears that; the gearboxes have two simplified
meshing locations that produce output speeds in geometric
progression. The deviations of output speeds related to
theoretical speeds lie in the permissible limits. Two simplified
meshing locations leads to save two gears from each gearbox,
the saving ratios in gears are: 25, 20, 16.6, and 16.6 % for 4, 6,
8 & 9 speed gearboxes respectively. The two case studies for
achieving 8 and 12 speeds through 4 and 6 structural diagrams
gearboxes respectively are considered in this paper.
Improvement in gears utilization factor in gearboxes with two
simplified meshing locations and driven by single speed electric
motors is 16.7, 15, 13, 15 % if it is compared with the
conventional one for gearboxes 4,6,8 &9 speeds respectively,
while it is 33, 30, 27, 30% if the same systems are driven by
double speed electric motors. For gearboxes have Structural
diagrams and conventional construction, driven by single speed
electric motors 4, 6, 8& 9, if they are constructed with two
Fig. (7) Kinematic Diagrams, Speed Char, Formula, and Some simplified meshing locations and driven by double speed
Notes for 8 Speed Gearbox with 4 Options; (Conventional and electric motors, the improvement in gears utilization factor
Two Simplified Meshing locations Driven by Single or Double reached to 83, 90, 93& 105% respectively. The actual speeds,
Speed Motor). speed deviations, and utilization factor of gears for various
gearboxes; (4, 6, 8& 9 speeds) using single or double speed
electric motors are calculated and listed in tables (8, 9, 10, 11,
12 and 13) and the relations are plotted in Figs. (9, 10 and
11).

Table (10) Theoretical, Actual Speeds and Speed Deviation for 12

Speeds Gearbox Driven by Double Speed Electric Motor.

Table (11) Gear Utilization Factor (UF) for Various Gearboxes

Using Single and Double Speed Motors.
Fig. (8) Kinematic Diagrams, Speed Chart, formula, and Some
Notes for 12 Speed Gearbox with 4 Options; (Conventional and
Two Simplified Meshing Locations Driven by Single Speed
Motor) and (Conventional and Two Simplified Meshing
Locations Driven by Double Speed Motor).

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Table (12) Saved Gears, saving ratio and Gear Utilization Factor
(UF) for Various Gearboxes for Conventional and Two Simplified
Meshing Location.

For certain structural diagrams of conventional gearboxes to

output 4, 6, 8 and 9 speeds, this paper concerned with studying
the effect of single and double speed electric motors on the
delivered speeds. The construction of previous gearboxes with Fig. (10) The Relation between Number of Speeds and Gear
two simplified locations, gear saving ratio on each case, gear Utilization Factor in Conventional and Two Simplified Meshing
utilization factor, and its final improvement when using two Locations Gearboxes Driven by Single and Double Electric
simplified meshing locations and driven by double speed Motors.
electric motor for each structural diagram are carried out.
In summary, this paper explained the characteristics of the
multistage gear boxes with simplified meshing locations driven
Table (13) Gear Utilization Factor (UF) for Various Conventional
and Two Simplified Meshing Locations Gearboxes Driven by by double speed electric motor design and proposed the
Double Speed Motors. appropriate design algorithm which can be used in the future to
computerize the design process. This proposed design can be
Double Speed Motor
carried out to find out the optimized design of the gearbox for
Speeds Conv. Simp. UF Conv. UF Simp. compact machine tools, helpful in saving time and reducing
2*4=8 8 6 1 1.333333 complexity in gear box design. The proposed design can
increase design reliability and decreases time and cost by
2*6=12 10 8 1.2 1.5
minimizing unnecessary redesign iterations. The design
2*8=16 12 10 1.333333 1.6 algorithm of using simulated strengthening to minimize the
2*9=18 12 10 1.5 1.8 geometrical volume of the gearbox, while satisfying spatial
constraints. The proposed algorithm has been applied to the
design of two gear boxes (8 and 12 speeds), and generated
considerably good design results in both aspects of the
dimensional and the configuration design. The designed
gearbox has been small-sized and minimized the number of
used gears, shafts, bearing and seals. The weight of a gear box
is proportional to the volume of the gears. This volume is
proportional to the sum of the gears width times the diameter
squared, of all the gears in the system. The proposed design
could result in light weight and ultra-light weight gear boxes.

Fig. (9) The Relation between Number of Speeds and Number of

Gears in Conventional and Two Simplified Meshing Locations
Gearboxes Driven by Single and Double Electric Motors.

697 www.ijaegt.com
 ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I Vol-03, Issue-06, June 2015

[9] Faisal S. Hussain, "Optimization of Gear Reduction Unit through Ray

Diagram", International Journal of Advanced Engineering and Global
Technology Vol-1, Issue-4, November 2013.
[10] Božidar Rosić, Aleksandar Marinkovic, Aleksandar Vencl, "Optimum
Design of Multispeed Gearboxes and Modelling of Transmission
Components", International Scientific Conference Heavy Machinery-
HM'05 Kraljevo, 28. June - 3. July 2005.
[11] Deb, Kalyanmoy and Jain, Sachin, “Multi- Speed gearbox design using
multi objective evolutionary algorithms”, Journal of mechanical
design” Journals of mechanical Design, Vol. 125, pp 609- 619,
September 2003.
[12] M. A. Nasser, F. R. Gomaa, M. A. Asy, Ahmed Deabs, " Computer Aided
Design of Multi-Stage Gearboxes|, International Journal of Advanced
Engineering and Global TechnologyVol-02, Issue-12, December 2014.
[13] M. A. Asy, "Design of Machine Tool Gearboxes Driven by Double Speed
Electric Motors", International Journal of Advanced Engineering and
Global Technology Vol-03, Issue-03, March 2015.

Fig. (11) The Relation between Number of Speeds, Gear

Utilization Factor for Gears in Case of Conventional and Two
Simplified Meshing Locations Gearboxes and Gear Max. UF
Improvement.

Conclusions:

1. Novel design of gearboxes with two simplified meshing

locations driven by double speed electric motor gives
output speeds in geometric progression is presented.
2. Gearboxes with two simplified meshing locations reduce
the number of used gears which improve its saving ratio.
The saving ratios lie between 16.7 and 25 % and reduces
the shaft lengths, gearbox size and cost.
3. Improvement in gears utilization factor in gearboxes with
two simplified meshing locations driven by single speed
electric motor is significant lies between 13and 15%, but
it is more significant if the same systems are driven with
double speed motors ranging between 27 and 33% for
gearboxes under study.

References

[1] Devendra Singh, Mohd. Suhaib, Kinematic Considerations in Gear Drives -

A Review, International Journal of Innovative Research in Science,
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