Title – Design of two-stage reduction

gearbox for a gear pump.

Div. – SY-ME(B)
Batch – B1, Group
01 Group Members:
-
1. Nikita Deshmukh (02)
2. Yash Deshmukh (03)
3. Atharva Deshpande (04)
4. Soham Dewoolkar (05)
5. Aniket Dharmadhikari (06)
6. Shreyansh Dhonde (07)
 Abstract

The design of a two-stage gearbox plays a crucial role in various mechanical

systems, enabling efficient torque transmission between an input and output shaft.
A two-stage gearbox consists of two sets of gears, each with its own gear ratio,
arranged in series. This arrangement allows for a higher torque output and a
broader range of speed reduction or increase compared to a single-stage gearbox.
Two-stage gearboxes find extensive use in automotive, manufacturing, and
robotics industries, where precise and controlled power transmission is essential.
Our project focuses on designing the two-stage reduction gearbox for gear pumps.
Most of the time, the gear pumps require high-output torque
 Methodology
 Given inputs/ parameters:
For Gear Design:
20deg Full depth
Input shaft Rotation = 1440 rpm
Power received by shaft 5 kW
Req. speed at the output shaft = 180 rpm
Steel Fe
Material for both pinion and gear 410
Cs (Service Factor) 1.25
Machining Grade 6
Sut (Ultimate Tensile Strength) 410 N/mm2
Assumed pitch-line velocity = 5 m/s
F.O. S 2

For Shaft Design:

Shaft Material= Steel FeF 580
Syt (yield Tensile Strength) = 580 N/mm2
Sut (Ultimate tensile strength) = 770 N/mm2

Bearing:
Single-row Deep Groove ball bearing
SKF Catalogue
 The basic procedure for designing any gearbox:

1) Gear Designing:-

Step 1: Find the unknown quantities.

 Knowing the inputs
 Based upon the inputs, find out the overall reduction ratio of the gearbox.
input rpm
i=
output rpm
In our case:
i=8
 Find out the ratio at each stage using the formula:
'
i =√ i

In our case:
i' = 2.824
 Find out the unknown rotational velocities of the shafts.
 Find out the velocity factor (for v< 10 m/ s):
3
Cv=
3+v
In our case:
Cv = 3/8
Step 2: Module calculation.
 Using Lewis’ equation find out the module for gears:
σ b . m .b .Y =( F . O. S ) . P eff

σ b = Endurance Strength of the gear =

Se =Sut /3

In our case:
Se= 410/3
m = module of the gears
b= face width
Y = Lewis Factor
 F. O. S = Factor of Safety
Peff = Effective load on the gear.
Cs
Peff = P
Cv t

Cs = Service Factor (Based upon the application of the gearbox).

Cv = Velocity Factor.
Pt = Tangential Load.
2. M t
Pt =
d

Mt = Torque transmitted:
6
60∗10 ∗kW
Mt=
2∗π∗n

n = rotational velocity
kW = power
In our case:
Mt = 93945 N-mm

 Find out the module based upon the above equations and given steps:

{ }
1
60∗106 kW . C s . FOS 3
m=[ ]

( )( )
π b S ut
z . n .C v . . .Y
m 3
In our case:
m = 6mm
Step 3: Dimension calculations for gear and pinion.
 Diameter of pinion (dp):
d p=m∗z p
In our case:
dp = 108 mm
  Diameter of gear (dg):
d g=m∗z g
In our case:
dg = 306 mm
 Face width (b):
b=10. m
In our case:
b = 60mm

Step 4: FOS calculation for Dynamic Load.

 Find out the FOS based upon the improved equation of the beam
Strength.

σ b . m .b .Y =( C s . Pt + P d )∗FOS

Pd = Dynamic Load:

21 v (C . e . b .+ Pt )
Pd =
21 v+ √ (C . e . b+ P t )
v = pitch-line velocity:
π .d .n
v= 3
60.10
In our case:
v= 2.874 m/s

C = Deformation Factor

In our case:
 C = 11400

e = error of combined pinion and gear.

e=e p +e g

ep = error in pinion.
Φ=m+0.25 √ d
e p=8+ 0.63 .Φ

eg = error in gear.(Find out the error in gear similar to that of

pinion
In our case:
e = 27.9519 x 10-3 mm
Step 5: Determining the surface hardness:
 Find out Contact Stress (K):

{ }
❑
60∗106 kW . C s . FOS
K=[ ]
π 2
( )
z . n .C v .
b
m
.Q . m3

 Find out the Brinell Hardness Number:

 2
BHN
K=o .165 .{ }
100
In our case:
BHN = 131.829

2) Shaft Designing:

 For Shaft Design, the bending moment and torsional moment plays a
crucial role. Therefore, it is necessary to find the Bending moments and
torsional moments acting on the shafts due to the pinion and gears.
 To find the bending moments and torsional moments it is required to
calculate the forces acting on the shaft because of pinion and gear in the
form of tangential load (for torque transmission and radial load for thrust
on the shaft)
 The Gear Placements have been done according to

Design Databook by PSG College of Technology

  The shaft that experiences max torsional moment and bending moment
will be designed.
 Weight of pinion and Gears are needed to include while calculation the
reaction forces.
Wg (Weight of gear) = 13.4 kg
Wp (Weight of pinion) = 2.4 kg

Step 1: Find out the tangential load and radial load due to pinion 1 on gear 2
and due to gear 2 on pinion 1
  To find out the tangential and radial loads we need to use following
formulas:
2. M t
Pt (Tangential load )=
d
And
Pr ( Radial Load ) =Pt tanΦ
Φ- pressure angle

In our case.
Due to gear 2 on pinion 2:

Ptp =1739.734 N ;
Prp=633.21 N
Due to pinion1on gear 1:
Pt g=614.0185 N ;
Pr g=633.21 N

Step 1: Find out the reaction forces on the bearings that are going to act
horizontally and vertically as well.

 The reaction forces will be found out using equilibrium conditions.

Σ F y =0
And
Σ M A =0

Fy – Horizontal Forces
MA – Moment at A

For Vertical forces FBD:

 In our case.
R Av =−321.185 N

R Bv=70.48 N

For Horizontal forces FBD:

In our case.

R Ah=948.7 N

R Bh=1405.062 N

Step 2: Find out the Horizontal and Vertical Bending Moment Diagram.
 For Vertical:

3876.4Nmm

-17648Nmm

For Horizontal: 77279.6125 Nmm

52178.5 Nmm

Step 3: Find out the resultant bending moment at G (gear) and P (pinion)
positions
  Resultant at G, Resg = 52322.263 N
 Resultant at P, Resp = 80407.609 N

Step 4: Finding out the torsional moment.

 Using the formula:
6
60. 10 . kW
Mt=
2. π . n

In our case:
Mt = 93945.6805 N-mm

Step 5: Find out the diameter of the shaft.

1
16
D=[
πτ
√ 2
( K b . M b ) +(K t . M t )2]3

 τ – Allowable shear stress:

τ = 0.75(0.3.Syt)
or
τ = 0.75(0.18.Sut)
(whichever is smaller)
In our case.
τ = 103.95 N/mm2
d = 35 mm

3) Bearing Selection:

The basic procedure for the selection of a bearing from the manufacturer’s
catalogue consists of the following steps:
Step 1: We have radial and axial force acting on the bearing and the shaft
diameter.
 Fr = 1436.77N
Fa = 0 N
(diameter of shaft) d = 35 mm ………(calculated in shaft design)

Step 2 :
Type: single-row deep groove ball bearing

Step 3:
Calculate the equivalent dynamic load from the equation.
P = Fr + Fa
Since there is no axial load,
P = Fr = 1436.77 N

Step 3: Make a decision about the expected bearing life and express the life
L10 in million revolutions.
Formula to calculate L10 is ,
60 n L10 h
L10= 6
10
Where, n = 509.11 rpm,
L10 h=50000 hrs
60∗509.11∗50000
So, L10= 6
10
L10=1527.33 million rev

Step 4:
Calculate the dynamic load capacity from the equation.
1
C=P ( L10 ) 3
Were,
P = Fr = 1436.77N
L10=1527.33 million rev
1
3
C=1436.77 ( 1527.33 )

C=16546.2 N
 Step 5:
Now select the bearing from SKF Bearing Catalogue using the C value
calculated above.

Sr. No Specification Value

1 Radial Load 1436.766 N
2 Rotational Velocity 509.11 rpm
3 Life 50000 hrs
4 No. of revolutiions 1527.33
5 Dynamic Load 16546.15
6 Bearing designation 6207

Table 1. Bearing Calc

To be on the safer side we neglected 15900 and selected 25500 from the above
catalogue.
Therefore, Bearing of Designation 6207 is selected.

Bearing selection is a critical process that directly impacts the performance,

reliability, and lifespan of machinery and mechanical systems. Considering
factors such as load, speed, environmental conditions, lubrication, and
maintenance requirements is essential for choosing the right bearing type, size,
and material. Collaboration with bearing manufacturers and industry experts
can provide valuable guidance in the selection process, leading to optimal
results and improved operational efficiency.

4) Gear Blank Design

Gear blank selection for Medium Sized Gear

Gears of addendum circle diameter from 150 mm to 400 mm are mostly forged
in open or closed dies.

a) When the gear is machined from bar stock, the material utilisation factor is
(1/3) when the gear is made. Utilisation of materials in forgings
factor is twice, or (3/2). This lowers the material's cost.
The construction of a forged gear is shown in Fig. It is made of three parts—
hub, web and rim. The web connects the hub with the rim. Holes are provided
in the web for clamping the gear blank during machining. It also reduces the
weight. The inner surface of the rim and the outer surface of the Fig. Forged
Gear hub are provided with draft for easy removal from the dies.

(a) The thickness of the rim (tr) up to the root circle diameter is taken as (2m) to
(3m).
(b) The thickness of web (b1) is taken as (0.2b) to (0.3b).
(c) The outer diameter of hub (d1) is taken as (1.5ds) to (2.0ds).
The main dimensions of the gear blank of forged gear are as follows:
(a) Pitch circle diameter = d ¢ = mz
(b) Addendum circle diameter = da = m(z + 2)
(c) Dedendum circle diameter = df = m(z – 2.5)
(d) Shaft diameter = ds
(e) Outer diameter of hub = d1 = (1.5ds) to (2.0ds) Spur Gears 669
(f) Length of hub = length of key or width of gear (maximum value)
(g) Width of web = b1 = (0.2b) to (0.3b)
(h) Inner diameter of rim = d3 = (df – 2tr)
(i) Outer diameter of rim = dedendum circle diameter = df
(j) Thickness of rim = tr = 2m to 3m
(k) Diameter of holes in web = d4 = (d3 – d1)/4
(l) Pitch circle diameter of holes = d2 = (d3 + d1)/2
(m) Width of rim = face width = b