Dr. D.Y.

Patil Institute of Technology

Pimpri, Pune - 411 018

Department of Mechanical Engineering

Design of transmission System

Unit – V
Design of Machine Tool Gear Box
Dr. K. B. Waghulde
 Unit – V Design of Machine Tool Gear Box

Introduction to Gear Boxes: -

The gearbox is a mechanical device used to increase the output torque or
to change the speed (RPM) of a motor. The shaft of the motor is connected
to one end of the gearbox and through the internal configuration of gears
of a gearbox, provides a given output torque and speed determined by the
gear ratio.
Gearboxes are used in many applications including machine tools,
industrial equipment, conveyors, and really any rotary motion power
transmission application that requires changes to torque and speed
requirements.

Purpose of using Gear Box:

The purpose of gear box is
 To convert single input speed into multiple output speeds
 It helps the engine to disconnect from driving wheels.
 It helps the running engine connect to the driving wheel smoothly
and without shock.
 It provides the leverage between engine and driving wheels to be
varied.
 This helps in reducing the engine speed in the ratio of 4 : 1 in case of
passenger cars and in a greater ratio in case of heavy vehicles like
trucks and lorries.
 It helps the driving wheels to drive at different speeds.
 It gives the relative movement between engine and driving wheels
due to flexing of the road spring.

Function of using Gear Box:

 Torque ratio between the engine and wheels should be varied for fast
acceleration and for climbing gradients.
 It provides means of reversal of vehicle motion.
  Transmission can disconnect from the engine by the neutral position
of the gearbox.
Types Gear Boxes:
Industrial gearbox:
 Helical gearbox
 Coaxial helical inline gearbox
 Bevel helical gearbox
 Skew bevel helical gearbox
 Worm reduction gearboxes
 Planetary gearbox
Automobile gearbox:
Manual transmission
 Sliding-Gear Transmission
 Constant-Mesh Transmission
 Pre-selector Transmission
Automatic transmission
 Torque Converter
 Automated-Manual Transmission
 Dual-clutch transmissions (DCT)
 Continuously variable transmission (CVT)

Need of multi-speed gear box in automobile:

The equation for cutting speed in machine tool is;
𝜋×𝐷×𝑛 1000 × 𝑣
𝑣= … … (1) ⟹𝑛= … … (2)
1000 𝜋×𝐷
Where; v – cutting speed in m/min and D – diameter of work-piece in mm
From above equation, in machine tool, each machining operation is carried
out at a specific speed. Different machining operations require different
speeds to perform operations. Also the spindle speeds are different for
different work-piece diameters.
Hence the machine tools need to operate with different spindle speed. To
obtained number of output speeds with a single input speed, the multi-
speed gear box is required in machine tools.
Basic Considerations in Design of multi-speed gear box:-
The ideal multi-speed gear box should satisfy the following conditions:
1. The speed range between two increments should be 10 to 15 %. A
larger range would further reduce the optimum use of the tool.
2. A number of speed ratios should be available to the operator without
stopping the machine.
3. The operator should be able to change speeds without going through
any intermediate sequence.
4. In multi-speed drives, only one set of gears in engagement at one time.
5. Due to compact system, axial length of the gear train is the least, if the
gear clusters are made sliding. But the sliding gear cluster should not
have more than three gears.
6. Only the gears which are used to achieve the gear ratio should be
rotating, whereas other gears of the gear box should not be engaged.
7. The number of shafts, gears and operating leavers should be minimum;
lesser the number of components, higher is the machine reliability.
8. Control unit should be designed ergonomically. It should be centralized
and should have all possible controls at one place.
9. The entire drive unit should be located inside the machine tool.

Laws of stepped regulation of speeds in multi-speed gear box; -

The ideal speed range in a machine tool would be the one where there
would be infinite number of speed ratios. This would allow an optimum
operation of a machine for any job diameter. Such speed regulation is
called as stepless regulation.
Let Nmin and Nmax is the minimum and maximum spindle speeds to be
achieved in z number of intermediate speed steps. These steps can be
arranged by following three laws.
1) Arithmetic Progression (AP)
2) Geometric Progression (GP)
3) Harmonic Progression (HP)

1) Arithmetic Progression: In arithmetic progression, the difference

between any two successive spindle speeds is constant.
Let,
Nmin – Minimum spindle speed in rpm
Nmax – Maximum spindle speed in rpm
a – Difference between two adjacent speed steps
z – Total number of spindle speed steps

Then difference between two adjacent speed steps is given by

𝑵𝒎𝒂𝒙 − 𝑵𝒎𝒊𝒏
𝒂=
𝒛−𝟏
Then different spindle speeds at respective step is given by,
𝑁1 = 𝑁𝑚𝑖𝑛 ; 𝑁2 = 𝑁𝑚𝑖𝑛 − 𝑎; 𝑁3 = 𝑁𝑚𝑖𝑛 − 2𝑎; … … 𝑁𝑧
= 𝑁𝑚𝑖𝑛 − (𝑧 − 1)𝑎 = 𝑁𝑚𝑎𝑥
The equation for cutting speed in machine tool is;
𝜋×𝐷×𝑛 1000 × 𝑣
𝑣= ⟹𝐷= … … (1)
1000 𝜋×𝑛
Where; v – cutting speed in m/min and D – diameter of work-piece in mm
Upper limit of diameter,
1000 × 𝑣
𝐷𝑘 =
𝜋 × 𝑁𝑘
Lower limit of diameter,
1000 × 𝑣
𝐷𝑘+1 =
𝜋 × 𝑁𝑘+1
Then diameter range that can be accommodated at a particular speed is
given by
1000 × 𝑣 1 1
Δ𝐷𝑘 = 𝐷𝑘 − 𝐷𝑘+1 ⟹ Δ𝐷𝑘 = ×( − )
𝜋 𝑁𝑘 𝑁𝑘+1

Advantage of Arithmetic Progression: - Multi-speed drive with

Arithmetic Progression is good in high spindle speed range.
Disadvantage of Arithmetic Progression: - Multi-speed drive with
Arithmetic Progression is poor in low spindle speed range.
2) Geometric Progression: In Geometric Progression, the ratio of any
two successive spindle speeds is constant and is called geometric
Progression ratio.
Let,
Nmin – Minimum spindle speed in rpm
Nmax – Maximum spindle speed in rpm
𝜙 – Geometric Progression ratio
z – Total number of spindle speed steps
Geometric Progression ratio is given by,
𝑁2 𝑁3 𝑁𝑧
𝜙= = …… =
𝑁1 𝑁2 𝑁𝑧−1
𝑁𝑚𝑎𝑥 𝑁2 𝑁3 𝑁𝑧 𝑁𝑚𝑎𝑥
𝑁𝑜𝑤; = × ……× ⟹
𝑁𝑚𝑖𝑛 𝑁1 𝑁2 𝑁𝑧−1 𝑁𝑚𝑖𝑛
= 𝜙 × 𝜙 × 𝜙 … … × 𝜙 (𝑧 − 1 𝑡𝑖𝑚𝑒𝑠)
𝑵𝒎𝒂𝒙
⟹ = 𝝓(𝒛−𝟏)
𝑵𝒎𝒊𝒏
𝟏
𝑵𝒎𝒂𝒙 (𝒛−𝟏) 𝟏
⟹ 𝝓=[ ] = [𝑹𝒏 ](𝒛−𝟏)
𝑵𝒎𝒊𝒏
𝑵𝒎𝒂𝒙
𝑾𝒉𝒆𝒓𝒆; 𝑹𝒏 = 𝒊𝒔 𝒄𝒂𝒍𝒍𝒆𝒅 𝒓𝒂𝒏𝒈𝒆 𝒓𝒂𝒕𝒊𝒐 𝒐𝒇 𝒔𝒑𝒊𝒏𝒅𝒍𝒆 𝒔𝒑𝒆𝒆𝒅
𝑵𝒎𝒊𝒏
The, different spindle speeds are given by
𝑁1 = 𝑁𝑚𝑖𝑛 ; 𝑁2 = 𝜙 × 𝑁𝑚𝑖𝑛 ; 𝑁3 = 𝜙 2 × 𝑁𝑚𝑖𝑛 ; … … 𝑁𝑧
= 𝜙 (𝑧−1) 𝑁𝑚𝑖𝑛 = 𝑁𝑚𝑎𝑥
The equation for cutting speed in machine tool is;
𝜋×𝐷×𝑛 1000 × 𝑣
𝑣= ⟹𝐷= … … (1)
1000 𝜋×𝑛
Where; v – cutting speed in m/min and D – diameter of work-piece in mm
Upper limit of diameter,
1000 × 𝑣
𝐷𝑘 =
𝜋 × 𝑁𝑘
Lower limit of diameter,
1000 × 𝑣
𝐷𝑘+1 =
𝜋 × 𝑁𝑘+1
Then diameter range that can be accommodated at a particular speed is
given by
1000 × 𝑣 1 1
Δ𝐷𝑘 = 𝐷𝑘 − 𝐷𝑘+1 ⟹ Δ𝐷𝑘 = ×( − )
𝜋 𝑁𝑘 𝑁𝑘+1
Advantage of Geometric Progression: -
1) Multi-speed drive with Geometric Progression gives constant loss of
economic cutting speed
in total speed range.
2) Multi-speed drive with Geometric Progression gives better gear box
design features.
Disadvantage of Geometric Progression: - Multi-speed drive with
Geometric Progression is poor in low spindle speed range.

Range Ratio with reference to machine tool gear box: The range ratio
for multi-speed gear box is the ratio of Maximum output speed of gear box
to minimum output speed of the gear box. It is denoted by Rn and given
by;
𝑵𝒎𝒂𝒙
𝑹𝒏 =
𝑵𝒎𝒊𝒏
The value of range ratio is large for general purpose machine tools, while
it is small for special purpose machine tool.
Machine Tool Range Ratio Rn
Centre Lathe 40 – 60
Milling Machine 30 – 50
Drilling Machine 15 – 30
Semi-Automatic
15 – 25
Lathe
Automatic Lathe 8 – 10
Grinding Machine 1 – 10
Geometric Progression Ratio: It is the ratio of two successive spindle
speeds. It is denoted by 𝜙 and given by;
𝑵 𝟐 𝑵𝟑 𝑵𝒛
𝝓= = …… =
𝑵 𝟏 𝑵𝟐 𝑵𝒛−𝟏
𝟏
𝑵𝒎𝒂𝒙 (𝒛−𝟏) 𝟏
𝝓=[ ] = [𝑹𝒏 ](𝒛−𝟏)
𝑵𝒎𝒊𝒏

Effect of Geometric Progression Ratio is given in the following table;

Lower Geometric Higher Geometric
Parameters Progression ratio Progression ratio
(𝝓) (𝝓)
Loss of economic cutting
Low High
speed
Number of speed steps
Large Small
(z)
Large and Compact and
Gear box
expensive inexpensive
Used in large sized Used in small sized
Use heavy duty heavy duty
machine tools machine tools

Significance of Geometric Progression ratio:

The multi-speed drive with Geometric Progression is commonly used in
tool drives due to following advantages;
1) Constant loss of Economic Cutting Speed in Total Speed range:
Loss of economic cutting speed is given by actual cutting speed minus
optimum cutting speed.
∆𝑣 = (𝑣𝑘 𝑜𝑟 𝑣𝑘−1 ) − 𝑣𝑜𝑝𝑡
The loss of economic cutting speed Maximum when the optimum cutting
speed lies at the middle of two speeds 𝑣𝑘 𝑎𝑛𝑑 𝑣𝑘−1 i.e. when;
 𝑣𝑘 + 𝑣𝑘−1 (𝜋𝐷𝑛𝑘 ) + (𝜋𝐷𝑛𝑘+1 )
𝑣𝑜𝑝𝑡 = = ⟹ 𝒗𝒐𝒑𝒕
2 2 × 1000
𝝅𝑫 𝒏𝒌 + 𝒏𝒌+𝟏
= ×( )
𝟏𝟎𝟎𝟎 𝟐
𝜋𝐷𝑛𝑘+1 𝜋𝐷 𝑛𝑘 + 𝑛𝑘+1
𝑇ℎ𝑒𝑛; ∆𝑣𝑚𝑎𝑥 = 𝑣𝑘+1 − 𝑣𝑜𝑝𝑡 = [ ]−[ ×( )]
1000 1000 2
𝝅𝑫 𝒏𝒌+𝟏 − 𝒏𝒌
∆𝒗𝒎𝒂𝒙 = ×( )
𝟏𝟎𝟎𝟎 𝟐
𝜋𝐷 𝑛 − 𝑛𝑘 𝑛𝑘+1
∆𝑣𝑚𝑎𝑥 × ( 𝑘+1 ) 𝑛𝑘+1 − 𝑛𝑘 −1
1000 2 𝑛𝑘
= = = 𝑛
𝑣𝑜𝑝𝑡 𝜋𝐷 𝑛𝑘 + 𝑛𝑘+1 𝑛𝑘 + 𝑛𝑘+1 𝑘+1
+1
×( ) 𝑛𝑘
1000 2
∆𝑣𝑚𝑎𝑥 𝜙−1 𝝓−𝟏
= ⟹ ∆𝒗𝒎𝒂𝒙 = ( ) × 𝒗𝒐𝒑𝒕
𝑣𝑜𝑝𝑡 𝜙+1 𝝓+𝟏

From above equation it is seen that for maximum loss of economic cutting
speed, ∆𝑣𝑚𝑎𝑥 to be constant over the total speed range of machine tool.
For this 𝜙 must be constant and 𝜙 is constant for Geometric Progression
only.
2) Compact and better gear box design: If the speed steps are obtained by
Geometric Progression, all the spindle speeds obtained by using
compound gear train arrangements. This reduces the number of gear pairs
and makes gear shifting convenient, thus the entire arrangement is
compact and economical in Geometric Progression.

3) Harmonic Progression: In harmonic Progression, the difference

between reciprocal of any two successive spindle speeds are constant. It
means the diameter change between two consecutive speeds range remain
constant.
Then diameter range that can be accommodated at a particular speed is
given by
1000 × 𝑣 1 1
Δ𝐷𝑘 = ×( − ) = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡
𝜋 𝑁𝑘 𝑁𝑘+1
 1 1 1 1 1 − 𝐶 𝑁𝑘
∴( − )=𝐶 ⟹( )= −𝐶 =
𝑁𝑘 𝑁𝑘+1 𝑁𝑘+1 𝑁𝑘 𝑁𝑘
𝑁𝑘+1 1
⟹ =
𝑁𝑘 1 − 𝐶 𝑁𝑘
𝑵𝒌+𝟏 𝟏
𝑹𝒂𝒕𝒊𝒐 𝒐𝒇 𝒔𝒖𝒄𝒄𝒆𝒔𝒔𝒊𝒗𝒆 𝒔𝒑𝒆𝒆𝒅𝒔; 𝝓𝒌 = =
𝑵𝒌 𝟏 − 𝑪 𝑵𝒌
The, different spindle speeds are given by
𝑁1
𝑁1 = 𝑁𝑚𝑖𝑛 ; 𝑁2 = ;
1 − 𝐶 𝑁1
𝑁1 𝑁1
𝑁2 1 − 𝐶 𝑁1 1 − 𝐶 𝑁1
𝑁3 = = =
1 − 𝐶 𝑁2 𝑁1 1 − 𝐶𝑁1 − 𝐶𝑁1
1−𝐶( )
1 − 𝐶 𝑁1 1 − 𝐶 𝑁1
𝑁1
⟹ 𝑁3 =
1 − 2 × 𝐶𝑁1
𝑁1
𝑆𝑖𝑚𝑖𝑙𝑎𝑟𝑙𝑦, 𝑁4 = 𝑎𝑛𝑑
1 − 3 × 𝐶𝑁1
𝑁1
𝑁𝑧 = = 𝑁𝑚𝑎𝑥
1 − (𝑧 − 1) × 𝐶𝑁1
Then diameter range that can be accommodated at a particular speed is
given by
1000 × 𝑣 1 1
Δ𝐷𝑘 = 𝐷𝑘 − 𝐷𝑘+1 ⟹ Δ𝐷𝑘 = ×( − )
𝜋 𝑁𝑘 𝑁𝑘+1
𝟏𝟎𝟎𝟎 × 𝒗
⟹ 𝚫𝑫𝒌 = ×𝑪
𝝅
Advantage of Harmonic Progression: - Multi-speed drive with
Harmonic Progression is good given in low spindle speed range.

Disadvantage of Arithmetic Progression: - Multi-speed drive with

Harmonic Progression is poor in high spindle speed range.
Standard values of Geometric Progression ratio (𝝓):
(How are the series of preferred numbers used in the design of multi-speed
gear box?)
In order to compromise between the loss of economic cutting speed and
the compactness of the drive, the value of 𝜙 is selected such that, 1 < 𝜙 ≤
2. The standard values of 𝜙 are based on the series of preferred numbers
and given in the following table;
Geometric Progression
Series
Ratio (𝝓)
𝜙40 40
𝑅 = √10 = 1.06
𝜙20 20
𝑅 = √10 = 1.12
𝜙10 10
𝑅 = √10 = 1.26
20/3
𝜙20/3 𝑅= √10 = 1.41
5
𝜙5 𝑅 = √10 = 1.58
4
𝜙4 𝑅 = √10 = 1.78
10/3
𝜙10/3 𝑅= √10 = 2.0

Recommended values of Geometric Progression ratio in Machine tool is

given in following table;
Recommended
Machine Tool
values of 𝝓
Heavy-duty machine tools 1.12
Large to medium size, general purpose
1.26
machine tool
Medium size, general purpose machine
1.41
tools
Medium to small size, general purpose
1.58
machine tool
Parameters required in kinematic design of multi-speed gear box:
The following parameters are required in kinematic design of multi-speed
gear box:
1) Maximum Spindle Speed (Nmax): It is given by the following
equation;
1000 × 𝑣𝑚𝑎𝑥
𝑁𝑚𝑎𝑥 = (𝑟𝑝𝑚)
𝜋 × 𝐷𝑚𝑖𝑛
Where;
Vmax – Corresponding maximum cutting speed (m/min)
Dmin – Minimum diameter of work-piece (mm)

2) Minimum Spindle Speed (Nmin): It is given by the following equation;

1000 × 𝑣𝑚𝑖𝑛
𝑁𝑚𝑖𝑛 = (𝑟𝑝𝑚)
𝜋 × 𝐷𝑚𝑎𝑥
Where;
Vmin – Corresponding minimum cutting speed (m/min)
Dmax – Maximum diameter of work-piece (mm)

3) Range Ratio𝑹𝒏: (Already discussed in above section)

4) Geometric Progression Ratio ( 𝝓 ): (Already discussed in above

section)

5) Number of spindle speed steps (z):

𝑹𝒏 = 𝝓𝒛−𝟏
log10 𝑅𝑛
(𝑧 − 1) log10 𝜙 = log10 𝑅𝑛 ⟹ (𝑧 − 1) =
log10 𝜙
log10 𝑅𝑛 log10 𝑅𝑛 + log10 𝜙 𝐥𝐨𝐠 𝟏𝟎 (𝑹𝒏 × 𝝓)
𝑧= + 1= ⟹𝒛=
log10 𝜙 log10 𝜙 𝐥𝐨𝐠 𝟏𝟎 𝝓
In above equation, the number of steps z is rounded off to the nearest
integer number which can be split into the multiples of 2 and 3. The
selected values of z are; 2, 3, 4, 6, 8, 9, 12, 16, 18, 24, 27, 32, 36.
6) Number of stages of gear box (N):
Total number of spindle speed steps; 𝑧 = 𝑝1 × 𝑝2 × … … … × 𝑝𝑁
Where;
p1 – Number of speed steps in first stage
p2 – Number of speed steps in second stage
pN – Number of speed steps in Nth stage
In order to obtain the required speed steps z using minimum number of
gears, it is necessary that all stages should have same number of speed
steps.
Therefore; 𝑝1 = 𝑝2 = ⋯ = 𝑝𝑁
𝑧 = 𝑝 × 𝑝 × … … … × 𝑝 (𝑁 𝑡𝑖𝑚𝑒𝑠) ⟹ 𝒛 = 𝒑𝑵
𝐥𝐨𝐠 𝟏𝟎 𝒛
log10 𝑧 = 𝑁 × log10 𝑝 ⟹𝑵=
𝐥𝐨𝐠 𝟏𝟎 𝒑
The value of number of speed steps per stage (p) is either 2 or 3
If the value of N obtained from equation is not an integer number, then
equation is modified as,
𝑧 = 2𝑁1 × 3𝑁2
Where;
N1 – Number of stages with two speed steps
N2 – Number of stages with three speed steps
N = N1 + N2

7) Speed of electric Motor:

The speed of electric motor nem is required to decide;
1) Speed of input shaft of the gear box and
2) Mode of transmission from electric motor to input shaft.
If the required speed of input shaft of the gear box is same as the motor
speed, then the motor is directly coupled to the input shaft. If the required
speed of input shaft is different than motor speed, then the two are
connected either by belt drive or gear drive.
Kinematic Diagram of Gear Box: (Gearing Diagram)
There are three steps to construct the kinematic diagram of gear box:
1) Structural Formulae
2) Structure Diagram
3) Ray Diagrams and speed charts
1) Structural Formulae: It is the mathematical expression giving the
distribution of number of speed steps in each stage and the number of
spindle speed steps by which two adjacent speed values of the each stage
are separated.
Let;
Nmin – Minimum spindle speed (rpm)
Nmax – Maximum spindle speed (rpm)
N1, N2, …… Nz – different spindle speeds (rpm)
z – Total number of spindle speed steps
𝜙 - Geometric Progression ratio
RN – Range ratio of spindle speed = Nmax / Nmin
p1, p2 ….pN – Number of speed steps in Ist stage, IInd stage, …. Nth stage.
N – Number of stages or transmission groups in gear box.
x1, x2,…. xN – Number of spindle speed steps by which two adjacent speed
values of particular stage are separated for Ist stage, IInd stage, …. Nth stage
respectively
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑝𝑖𝑛𝑑𝑙𝑒 𝑠𝑝𝑒𝑒𝑑 𝑠𝑡𝑒𝑝𝑠; 𝑧 = 𝑝1 × 𝑝2 × … … … × 𝑝𝑁
Expression for structural formulae;
𝑧 = 𝑝1 (𝑥1 ) × 𝑝2 (𝑥2 ) × … … … × 𝑝𝑁 (𝑥𝑁 )
If difference between two adjacent speed values is equal to one spindle
speed step then, x = 1
If difference between two adjacent speed values is equal to two spindle
speed steps then x = 2.
Values of x1, x2, …. xN
𝑥1 = 1; 𝑥2 = 𝑝1 ; 𝑥2 = 𝑝1 × 𝑝2 … … ; 𝑥𝑁 = 𝑝1 × 𝑝2 × … … × 𝑝𝑁−1
By rearranging x1, x2,…. xN, 𝑁! combinations of x1, x2, …. xN can be
obtained for the same combination of p1, p2 ….pN
𝑇𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑟𝑢𝑐𝑡𝑢𝑟𝑎𝑙 𝑓𝑜𝑟𝑚𝑢𝑙𝑎𝑒 = (𝑁!)2
Feasible structural formulae:
 𝑧
1) If = integer, structural formula is feasible.
𝑃𝑘 ×𝑋𝑘
𝑧
2) If ≠ integer, structural formula is not feasible.
𝑃𝑘 ×𝑋𝑘

Transmission Range: It is the ratio of maximum speed ratio obtained in a

stage to the minimum speed ratio obtained in a stage. It is given by;
(𝑖𝑚𝑎𝑥 )𝑠𝑡𝑎𝑔𝑒
(𝑖𝑔 )𝑠𝑡𝑎𝑔𝑒 =
(𝑖𝑚𝑖𝑛 )𝑠𝑡𝑎𝑔𝑒
Where;
(𝑖𝑔 ) − 𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑛𝑔𝑒 𝑜𝑓 𝑎 𝑠𝑡𝑎𝑔𝑒
𝑠𝑡𝑎𝑔𝑒
(𝑖𝑚𝑎𝑥 )𝑠𝑡𝑎𝑔𝑒 − 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑖𝑛 𝑎 𝑠𝑡𝑎𝑔𝑒
(𝑖𝑚𝑖𝑛 )𝑠𝑡𝑎𝑔𝑒 − 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑖𝑛 𝑎 𝑠𝑡𝑎𝑔𝑒
For a machine tool gear box, the transmission range should not exceed 8;
(𝑖𝑔 ) ≤8
𝑠𝑡𝑎𝑔𝑒

1) Structural Diagram: The structural formulae which describe the

kinematic structure of the gear box are represented in the form of special
graphs known as structural diagrams.
Procedure for Constructing Structure Diagram:
Let; N – Number of stages of gear box and z – number of spindle speed
steps.

1) Draw (N + 1) number of vertical lines at a convenient distance from

each other. Each vertical line represents one shaft with the first line
representing the input shaft and the last line representing the output
shaft. Each zone between two adjacent vertical lines represents a
transmission group or stage.
2) Draw z number of horizontal lines at intervals equal to log10 𝜙. Each
horizontal line represents a spindle speed.
On structure diagram;
𝑁2 = 𝑁1 × 𝜙
log10 𝑁2 = log10 𝑁1 × log10 𝜙
𝑆𝑖𝑚𝑖𝑙𝑎𝑟𝑙𝑦; log10 𝑁3 = log10 𝑁2 × log10 𝜙
3) Using the structural formula;
𝑧 = 𝑝1 (𝑥1 ) × 𝑝2 (𝑥2 ) × … … … × 𝑝𝑁 (𝑥𝑁 )
Plot the values of p1, p2 ….pN on vertical lines II, III, IV, …. at distances
x1, x2, …. xN respectively, as shown in above figure.
4) Draw the lines representing transmission between the output shaft and
input shaft.

Examples of Structure Diagram: The structure diagrams for the six

structural formulae given by equations are as follows with z = 12 and N =
3;
1) 2(1) 3(2) 2(6) 2) 2(1) 3(4) 2(2) 3) 2(3) 3(1) 2(6)
4) 2(6) 3(1) 2(3) 5) 2(2) 3(4) 2(1) 6) 2(6) 3(2) 2(1)
Salient Features of Structure Diagram: The structure diagram gives the
following information’s:
1) The number of shafts in gear box;
2) The number of gears on each shaft;
3) The order of charging transmissions in individual transmission groups
to get the desired spindle speed;
4) The transmission range of each transmission group.

Limitations of Structure Diagram: The structure diagram cannot give

the following information’s:
1) The spindle speeds;
2) The range ratio of spindle speeds;
3) The motor speed;
4) The Geometric Progression ratio.

Types of Structure Diagrams: The structure diagrams are of two types

1) Open Type; 2) Crossed Type

Selection of Optimum Structure Diagram:

An optimum structure diagram is one which results in a compact gear box
with less number of gears, shafts and shifting levers.
An optimum structure diagram should satisfy the following conditions;
1) Transmission range restriction,
2) Minimum total shaft size,
 3) Minimum number of gears on output shaft,
4) Maximum speed ratio in last stage,
5) Number of speed steps in any stage should not be more than three,
6) Location of input point closer to motor speed.

1) Transmission range restriction: It is the ratio of maximum speed ratio

obtained in a stage to the minimum speed ratio obtained in a stage. It is
given by;
(𝑖𝑚𝑎𝑥 )𝑠𝑡𝑎𝑔𝑒
(𝑖𝑔 )𝑠𝑡𝑎𝑔𝑒 =
(𝑖𝑚𝑖𝑛 )𝑠𝑡𝑎𝑔𝑒
Where;
(𝑖𝑔 ) − 𝑇𝑟𝑎𝑛𝑠𝑚𝑖𝑠𝑠𝑖𝑜𝑛 𝑟𝑎𝑛𝑔𝑒 𝑜𝑓 𝑎 𝑠𝑡𝑎𝑔𝑒
𝑠𝑡𝑎𝑔𝑒
(𝑖𝑚𝑎𝑥 )𝑠𝑡𝑎𝑔𝑒 − 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑖𝑛 𝑎 𝑠𝑡𝑎𝑔𝑒
(𝑖𝑚𝑖𝑛 )𝑠𝑡𝑎𝑔𝑒 − 𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑠𝑝𝑒𝑒𝑑 𝑟𝑎𝑡𝑖𝑜 𝑜𝑏𝑡𝑎𝑖𝑛𝑒𝑑 𝑖𝑛 𝑎 𝑠𝑡𝑎𝑔𝑒
For a machine tool gear box, the transmission range of stage should not
exceed 8; (𝑖𝑔 ) ≤8
𝑠𝑡𝑎𝑔𝑒
2) Minimum Total Shaft size: The diameter of any shaft is determined by;
𝜋
𝑇𝑜𝑟𝑞𝑢𝑒 𝑡𝑟𝑎𝑛𝑠𝑚𝑖𝑡𝑡𝑒𝑑; 𝑇 = × 𝜏 × 𝑑3
16
The diameter of shaft is determined at the lowest speeds at which the shaft
rotates. Node method of optimization: In case of optimum structure
diagram, the sum of diameters of all shafts is minimum, that is, ∑𝑁+1
1 𝑑=
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 and verified by node method of optimization. The node is the
point from which the Ray starts or at which the ray terminates. The node
method is described below:
a) In all candidate structure diagrams, number the nodes from maximum
spindle speed for each shaft as shown in above figure. The higher node
number indicates higher torque acting on the shaft.
b) For each structure diagram, select the transmission line with higher
node numbers.
c) For each structure diagram, take sum of node numbers for selected
transmission line as per following table.

Struct Nodes on
Transmission Line Σ
ure
(Node Remarks
diagra Shaft Shaft- Shaft-
m Numbers)
-I II III
a 1 4 6 11 Optimum structure
diagram
b 1 6 6 13
c 1 5 6 12

d) The sum of node numbers is proportional to the sum of shaft diameters.

The optimum structure diagram is one with minimum value of Σ (Node
Numbers)
3) Minimum number of gears on output shaft: The number of gears on the
spindle shaft should be as minimum as possible.
4) Maximum speed ratio in last stage: The speed ratio in last stage should
be as maximum as possible. For optimum structure diagram, 𝑥1 < 𝑥2 <
𝑥3 … … … < 𝑥𝑁
5) Number of speed steps in any stage should not be more than three: The
number of speed steps in any transmission group should not exceed three,
through in exceptional cases it may be four.
6) Location of input point closer to motor speed: In order to avoid large
transmission ratio between the motor shaft and the input shaft should be
located closer to motor speed.
Speed diagrams and Ray diagrams:
The structure diagram can neither give the spindle speeds nor range ratio
of spindle speed. These parameters are determined by constructing the
speed diagrams and Ray diagrams.

(a)Speed Diagram

(b) Ray Diagram

Procedure for constructing Speed diagrams:

Let, N – Number of stages of gear box, z – Number of spindle speed steps.
1) Draw one vertical line for electric motor and (N+1) number of vertical
lines for shafts. Sometimes, the vertical line for electric motor may
 coincide with the vertical line for input shaft. Each zone between two
adjacent vertical lines represents a transmission group or stage.
2) Draw horizontal lines at a distancelog10 𝜙. Beginning with nmin mark
the successive spindle speeds and motor speed on horizontal lines from
bottom to top. The number of horizontal lines are determined as ; if
𝑛𝑧 > 𝑛𝑒𝑚 : draw z number of horizontal lines. if 𝑛𝑧 < 𝑛𝑒𝑚 : draw as
many additional horizontal lines as are necessary to locate nem to the
speed chart.
3) Using the structural formula;
𝑧 = 𝑝1 (𝑥1 ) × 𝑝2 (𝑥2 ) × … … … × 𝑝𝑁 (𝑥𝑁 )
Plot the values of p1, p2 ….pN on vertical lines II, III, IV, …. at distances
x1, x2, …. xN respectively,

4) Draw the lines representing transmission between the output shaft and
input shaft.
5) Complete the speed diagram for spindle speeds as shown in above
figure.
6) The lines joining points of adjacent shafts in a speed diagram represent
the stage speed ratios.
a) If the line is horizontal: istage = 1 and there is no speed change.
b) If the line is inclined upwards from left to right: 𝑖𝑠𝑡𝑎𝑔𝑒 > 1 and there
is speed increase.
c) If the line is inclined upwards from left to right: 𝑖𝑠𝑡𝑎𝑔𝑒 < 1 and there
is speed reduction.
Salient Features of Speed Diagrams: The Ray diagrams and speed
diagrams give the following information:
1. The number of shafts in gear box;
2. The number of gears on each shaft;
3. The order of charging transmissions in individual transmission groups
to get the desired spindle speed;
4. The transmission range of each transmission group;
5. The spindle Speeds;
6. The Range Ratio of spindle speeds;
7. The motor speed and;
8. The Geometric Progression Ratio.

Selection of Optimum speed diagrams: The procedure for the selection

of optimum speed diagram is same as the procedure for the selection of
optimum structure diagram.

Comparison between structure diagram and speed diagrams:

Sr. Structure Diagram Speed Diagram

No.

The structure diagram contains The speed diagram contains one

(N+1) vertical lines for input vertical line for electric motor shaft
2 shaft, Intermediate shafts and and (N+1) vertical lines for input
output shaft. shaft, Intermediate shafts and output
shaft.
The structure diagram contains The speed diagram contains the
the number of horizontal lines number of horizontal lines required
3
equal to the number of spindle for locating all spindles speeds as
speed steps. well as electric motor speeds.
The structure diagram does not The speed diagram gives all spindle
4
give the spindle speeds. speeds.
 The structure diagram does not The speed diagram gives the Range
5 give the Range Ratio of Ratio of spindle speeds.
spindle speeds.
The structure diagram does not The speed diagram gives the
6 give the Geometric Geometric Progression Ratio.
Progression Ratio.
The structure diagram does not The speed diagram gives the
7
give the electric motor speed. electric motor speed.

General Guidelines in Developing Kinematic Diagram (Gearing

Diagram) for Multi-speed gear box: The general guidelines to be
followed while developing the kinematic diagram for multi-speed gear
box are as follows:
1) Overall dimensions of gear-box should be minimum: The overall
dimensions of gear box should be as minimum as possible.
2) Avoid interference on gears: The number of teeth on the smallest gear
of the gear box should be such that, there is no interference. For 200 full
depth involute tooth system, 𝑧 ≥ 18.
3) If gear pairs on parallel shafts have same module, the sum of
number of teeth on mating gears must be same:

Let;
z1i, z1o – Number of teeth on first gear pair;
z2i, z2o – Number of teeth on second gear pair;
z3i, z3o – Number of teeth on third gear pair
m – Module for all gears (mm)
a – centre distance between axes of two shafts.
From above figure
(𝑚𝑧1𝑖 + 𝑚𝑧1𝑜 )
𝐹𝑜𝑟 𝑓𝑖𝑟𝑠𝑡 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑔𝑒𝑎𝑟, 𝑎 =
2
(𝑚𝑧2𝑖 + 𝑚𝑧2𝑜 )
𝐹𝑜𝑟 𝑠𝑒𝑐𝑜𝑛𝑑 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑔𝑒𝑎𝑟, 𝑎 =
2
(𝑚𝑧3𝑖 + 𝑚𝑧3𝑜 )
𝐹𝑜𝑟 𝑡ℎ𝑖𝑟𝑑 𝑝𝑎𝑖𝑟 𝑜𝑓 𝑔𝑒𝑎𝑟, 𝑎 =
2

From above equations;

(𝒛𝟏𝒊 + 𝒛𝟏𝒐 ) = (𝒛𝟐𝒊 + 𝒛𝟐𝒐 ) = (𝒛𝟑𝒊 + 𝒛𝟑𝒐 )
Also;
𝑧1𝑜 𝑧2𝑜 𝑧3𝑜
= 𝑖1 ; = 𝑖2 ; = 𝑖3
𝑧1𝑖 𝑧2𝑖 𝑧3𝑖
The number of teeth on the smallest teeth is taken as 18. The smallest gear
is a pinion of a gear pair which gives maximum Transmission ratio.
From figure;
𝑧2𝑜
𝑧2𝑜 = 𝑧𝑚𝑖𝑛 ⟹ 𝑧2𝑖 =
𝑖2
By knowing 𝑧2𝑜 𝑎𝑛𝑑 𝑧2𝑖 ; the number of teeth on remaining gears are
calculated.
4) Deviation of actual spindle speeds from calculated spindle speeds
must not exceed
𝟏𝟎(𝝓 − 𝟏)%:
The rounding off of the calculated number of teeth to nearest integer (First
preference vale as per Choice - 1) lead to difference between the actual
and calculated spindle speeds. The deviation of actual spindle speeds from
calculated spindle speeds must not be exceed 10(𝜙 − 1)%.
5) Minimum difference between numbers of teeth on adjacent gears in
a change gear block must be at least four:

When cluster gear block on input shaft is shifted towards right for
changing the speed as shown in above figure, the metal to metal clash
between gears z1i and z2o can be avoided only if,
𝐷𝑖𝑠𝑡𝑎𝑛𝑐𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑎𝑥𝑒𝑠 𝑜𝑓 𝑔𝑒𝑎𝑟𝑠 𝑧2𝑖 𝑎𝑛𝑑 𝑧20
≥ 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑔𝑒𝑎𝑟 𝑧1𝑖
+ 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 𝑟𝑎𝑑𝑖𝑢𝑠 𝑜𝑓 𝑔𝑒𝑎𝑟 𝑧2𝑜

(𝑚𝑧2𝑖 + 𝑚𝑧2𝑜 ) (𝑚𝑧1𝑖 + 2ℎ𝑎 ) (𝑚𝑧2𝑜 + 2ℎ𝑎 )

≥ +
2 2 2
Where, ℎ𝑎 − 𝐴𝑑𝑑𝑒𝑛𝑑𝑢𝑚 = 𝑚𝑜𝑑𝑢𝑙𝑒 (𝑚)
(𝑚𝑧2𝑖 + 𝑚𝑧2𝑜 ) (𝑚𝑧1𝑖 + 2𝑚) (𝑚𝑧2𝑜 + 2𝑚)
≥ +
2 2 2
(𝑚𝑧2𝑖 + 𝑚𝑧2𝑜 ) ≥ (𝑚𝑧1𝑖 + 𝑚𝑧2𝑜 + 4𝑚)
𝒛𝟐𝒊 − 𝒛𝟏𝒊 ≥ 𝟒
6) Spacing between two adjacent gears on the shaft must be greater
than twice the face width:

The spacing between the two adjacent gears on the shaft should be such
that one gear pair gets completely disengaged before the next pair begins
to mesh. Minimum spacing between adjacent gears must be 𝑙 > (2𝑏).

Procedure for Kinematic Design of Multi-speed Gear Box for

Machine Tool:
The following procedure is adopted in kinematic design of multi-speed
gear box for machine tools:
1) The Data available is; Minimum diameter of work-piece dmin and
corresponding maximum cutting speed vmax. Maximum diameter of work-
piece dmax and corresponding minimum cutting speed vmin.
2) Calculate maximum and minimum spindle speeds by following
equations;
1000 × 𝑣𝑚𝑎𝑥 1000 × 𝑣𝑚𝑖𝑛
𝑁𝑚𝑎𝑥 = ; 𝑎𝑛𝑑 𝑁𝑚𝑖𝑛 =
𝜋 × 𝑑𝑚𝑖𝑛 𝜋 × 𝑑𝑚𝑎𝑥
𝑁𝑚𝑎𝑥
3) Calculate range ratio spindle speeds by equation; 𝑅𝑛 =
𝑁𝑚𝑖𝑛

4) Select Geometric Progression ratio 𝜙 based on the type of machine tool.

5) Calculate the total number of spindle speed steps by following
log10(𝑅𝑛 𝜙)
equation; 𝑧 =
log10 𝜙

6) List all the spindle speeds from 𝑁𝑚𝑖𝑛 𝑡𝑜 𝑁𝑚𝑎𝑥 𝑎𝑠 𝑁1 , 𝑁2 , 𝑁2 , … … . 𝑁𝑧

7) Decide the number of stages (N) in gear box as per following
conditions;
log10 𝑧
𝑁=
log10 𝑝
𝑤ℎ𝑒𝑟𝑒, number of speed steps per stage (𝑝) is either 2 or 3
If the value of N obtained from equation is not an integer number, then
equation is modified as,
N = N1 + N2; where; 𝑧 = 2𝑁1 × 3𝑁2
8) Write the different structural formulae and construct corresponding
structure diagrams.
𝑧 = 𝑝1 (𝑥1 ) × 𝑝2 (𝑥2 ) × … … … × 𝑝𝑁 (𝑥𝑁 )
9) Select the optimum structure diagram.
10) Select the electric motor speed by knowing the speed of input shaft.
11) Construct the optimum speed diagram from optimum structure
diagram.
12) The gearing diagram is constructed by calculating the number of teeth
on different gears.

Deviation Diagram for Multi-Speed Gear Box: Due to rounding off of

the calculated number of teeth on gears to nearest integers, the actual
spindle speeds nact available on the machine tool are deviated from the
calculated spindle speeds nth. Then speed deviation is given by the
following equation;
Δ𝑛 = 𝑛𝑎𝑐𝑡 − 𝑛𝑡ℎ
Then percentage speed deviation is given by;
% 𝑆𝑝𝑒𝑒𝑑 𝐷𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛
𝐴𝑐𝑡𝑢𝑎𝑙 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑆𝑝𝑒𝑒𝑑 − 𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑆𝑝𝑒𝑒𝑑
=
𝐶𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑆𝑝𝑖𝑛𝑑𝑙𝑒 𝑆𝑝𝑒𝑒𝑑
× 100
𝑛𝑎𝑐𝑡 − 𝑛𝑡ℎ
% 𝑆𝑝𝑒𝑒𝑑 𝐷𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 = × 100
𝑛𝑡ℎ
Conditions on speed deviations are;
1) % 𝑆𝑝𝑒𝑒𝑑 𝐷𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛 < 10 (𝜙 − 1)%
2) ∑𝑧𝑖=1 % 𝑠𝑝𝑒𝑒𝑑 𝑑𝑒𝑣𝑖𝑎𝑡𝑖𝑜𝑛𝑠 𝑎𝑡 𝑎𝑙𝑙 𝑠𝑝𝑒𝑒𝑑𝑠 = 0

The deviation diagram, which is the plot of percentage speed deviations

against the calculated spindle speeds is shown in above figure.
1 Explain Basic Considerations in design of multi-speed gear box?
2 State the importance of multi-speed gear box.
3 State and explain the parameters used in kinematic design of gearbox.
4 What is the need of multi-speed gear box in drive system of a
machine tool?
5 What is the need of multi-speed gear box in machine tools or
automobiles? State and explain the basic considerations in design of
multi-speed gear box.
6 What are the various laws can be used to decide the rpm value of
different steps in machine tool gear box. Explain any one law with
example.
7 What are the various laws for stepped regulation of speeds in multi-
speed gear boxes? State the advantages and disadvantages for them.
8 State the law of geometric progression used in machine tool gearbox
design. State its advantages and disadvantages.
9 Write the advantages and disadvantages of arithmetic, geometric and
Harmonic progression.
10 Explain the significance of geometric progression ratio.
11 Compare different laws of regulation of speed in multispeed gear box.
12 Differentiate between arithmetic, geometric and Harmonic
progressions in case of design of gear box.
13. List the major advantages and disadvantages of geometric
progression for speed regulation in a gear box.
14 Explain the term: Maximum loss of economic cutting speed.
15 Explain the term range ratio with reference to machine tool gear box
design.
16 In multi-speed gear box, geometric progression ratio is selected in the
range of 1 to 2, Justify?
17 How are the series of preferred numbers used in the design of multi-
speed gear box?
18 Explain the following terms with reference to machine tool gear box.
How these parameters are decided while designing machine tool
drives, 1) Range ratio; 2) Number of transmission group of stages.
19 What are the different parameters considered in kinematic design of
multi-speed gear box? Explain any two in brief.
20 What is structural formula? Write any three structural formulae for
twelve speed gear box.
21 Justify the statement: All the structural formulae of the form z =
P1(x1) P2(x2) ….. Pn(xN) cannot be converted into structural diagrams,
and hence are not feasible
22 Explain the term: Transmission range with reference to machine tool
gear box.
23 Explain through significance of node method of optimization, Why
structure diagram with minimum nodal sum is optimum?
24 Prove that Difference between numbers of teeth on adjacent gears in a
change gear block must be four or more. Why this condition is
applicable only if the compound gear is a cluster of three gears and
not of two gears?
25 Justify the statement, The difference between numbers of teeth of
successive gears in a change gear box must be greater than four.
26 Write the procedure for kinematic design of multi-speed gear box for
machine tools.
27 Find the rpm values and diameter range served by each rpm in
geometric, harmonic and arithmetic progressions and compare them
based on the following conditions:
Minimum speed, n1 = 30 rpm; Maximum speed, n2 = 385 rpm,
Number of speed steps, z = 12; Cutting speed, v = 20 m/min; Draw
the gearing (kinematic) diagram as per the Geometric Progression.
28 A machine tool requires 12 speed in the range of nmax = 1000 rpm to
nmin = 180 rpm. List the most suitable speeds to be provided
29 Find the range ratio, progression ratio and spindle speeds for the
following data, Nmin = 100 rpm; Nmax = 1800 rpm and Number of
speed steps = 8. Also draw all possible structure diagrams.
30 Draw the structure diagrams and gear box layout for the following
equations,
a) 2 (1) 2 (2); b) 3 (1) 2 (3); c) 2 (1) 2 (2) 2 (4); d) 3
(1) 2 (3) 2 (6)
31 Draw the structure diagrams and gear box arrangements for the
following equations,
a) 2 (1) 3 (2); b) 2 (3) 3 (1); c) 3 (1) 2 (3); d) 3 (2) 2
(1)
32 Draw speed diagram and layout for a six speed gear box having the
following structural formula: 1) 2 (3) 3 (1); 2) 2 (1) 3 (2). The
output speeds are 160 rpm minimum and 1000 rpm maximum. The
motor shaft speed is 1440 rpm.
33 Draw structural diagrams and gear box diagrams for the following
structural formulae of twelve speed gear box. Also determine the
maximum transmission range for each of the structural formulae for
R5 series.
1) Z = 2(6) 2(1) 3(2); 2) z = 2(3) 2(6) 3(1); 3) z = 2(6) 2(3)
3(1)
34 Draw structural diagrams for the following structural formulae and
identify the optimum structural formula out of them. Draw the
gearing diagram for the optimum structural formula.
1) 2(1) 3(2); 2) 2(3) 3(1); 3) 3(2) 2(1); 4) 3(1) 2(3)
35 Draw symmetric structure diagrams for the following structural
formulae and identify the optimum structural formula out of them
giving justification.
1) 2(1) 2(2) 3(4); 2) 2(2) 2(1) 3(4); 3) 2(6) 2(1) 3(2); 4)
2(1) 2(6) 3(2)
36 A 2 x 2 drive is required to be designed for transmitting speeds
starting from 400 rpm with a geometric progression ratio of 1.4. Draw
a suitable structure and speed diagram. Also draw the layout of the
gear box and determine the number of teeth on each gear.
37 For the design of a 2 X 3 machine tool gear box with following
specification, Nmin = 100 rpm; Nmax = 960 rpm and GP ratio = 1.26.
1) Draw structure diagrams; 2) Draw Ray diagram and speed chart.
38 It is required to design a 2 X 3 Multi-speed gear box for a lathe
machine operation with following specification. Nmin = 120 rpm; Nmax
= 1500 rpm and GP ratio = 1.41. a) Write structural formulae and
Draw structural diagrams; b) Draw Ray diagram and speed chart. C)
Find the number of teeth of each gear.
39 Draw the structural and speed diagram for a gear box having
operating speed range 30 rpm to 700 rpm. Use R5 series with
standard spindle speed. The gear box is connected to a motor, running
at 1440 rpm through a pair of pulleys.
40 A 9 speed gear box is to be connected to a motor running at 720 rpm
through a belt drive. The gear box is to have a minimum speed of
31.5 rpm and a maximum speed of 500 rpm. Using standard spindle
speeds. a) Draw the structure and speed diagram for the arrangement;
b) Draw the gear box; c) Select suitable standard pulley diameter for
connecting the motor to the gear box shaft. The standard pulley
diameters are based on R20 series with a diameter starting from 80
mm.
41 A 9 speed machine tool gear box is to be designed for following
specification; Nmin = 100 rpm; Nmax = 630 rpm and Progression ratio
= 1.26
1) Draw structural diagrams and select the best one; 2) Draw Ray
diagram and speed chart; 3) Find the number of teeth of each gear.
42 A six speed gear box is to be designed for a machine tool drive. The
spindle speeds range between 200 rpm and 1200 rpm. If the gear box
is driven by 8 kW, 1200 rpm electric motor through the belt drives. 1)
Draw the speed diagram and 2) draw the gearing diagram.
43 A multi-speed gear box is to be designed for a small size, general
purpose machine tool for spindle speeds varying between 200 rpm to
2000 rpm. If the recommended geometric progression ratio is as per
R5 series: 1) Draw the structure diagrams for machine tool gear box;
2) select the optimum structure diagram. If the gear box is to be
driven by 2880 rpm, three phase A.C. motor through a belt drive,
Determine the ratio of belt pulley diameters.
44 A four speed gear box is to be used for a machine tool drive. The
spindle speeds range between 200 rpm to 800 rpm. Design the gear
box and draw deviation diagram.
45 Draw layout of machine tool gear box having structural formulae 3(1)
3(3)
46 A six speed gear box is to be designed for a machine tool drive. The
spindle speeds range between 150 rpm and 1000 rpm. If the gear box
is driven by 5 kW, 1000 rpm electric motor through the belt drives.
1) Draw the speed diagram; 2) draw the gearing diagram; 3)
determine the number of teeth on gears; 4) Select the diameters of
pulleys for belt drive.
The standard pulley diameters are: 80, 90, 100, 112, 125, 140, 160,
180, 200, 224, 250, 280, 290, 300, 310, 355, 375, 400, 450, 500 mm.
Assume same module for all gears.
47 A nine speed sliding mesh gearbox based on R5, is to be designed for
the speeds starting from 120 rpm. It is to be driven by three phase
induction motor running at 1440 rpm.
1) List all speeds for the proposed gear box; 2) Write all structure
formulae; 3) Draw speed Ray diagram.
48 A nine speed gearbox, with speeds starting from 100 rpm and based
on R5 series, is used for transmitting 10 kW power from a motor
running at 1440 rpm. Assuming the minimum number of teeth in all
stages as 20;
1) Draw the symmetric structure diagram; 2) determine the number of
 teeth on all gears and; 3) Draw the deviation diagram of designed
gearbox.
49 Read the structure diagram given below and answer the following
questions:
a) What is geometric progression ratio and range ratio of this gear
box?
b) Write structure formula for this gearbox;
c) What is the speed of input shaft of the gear box?
d) Draw schematic layout diagram of the gearbox and calculate
number of teeth on each gear by assuming 20 teeth on smallest gear
of each stage.