ASSOSA UNIVERSITY
COLLEGE OF ENGINERRING
DEPARTMENT OF MECHANICAL
NAME OF STUDENTS ID NO
YIGREMACHEW BIZUALEW………………………………………………….0491/12
CHAPTER ONE
Gear design
1.1. Introduction
Gear drives consist of gears as main transmission elements mounted on shafts supported by
bearings. In open gear drives the bearings carrying shafts are supported in rigid frames while in
closed gear drives bearing are supported in the casing or body, normally made in two halves and
may be cast or welded. The casing also stores lubricant at the bottom and is designed to keep the
body cool, drain the oil for oil change, hooks for lifting and windows for observing the gears.
The design of gear drives involves:
Design of gears for power to be transmitted and velocity ratio
Design of shafts
Selection of rolling contact bearings or design of sliding contact bearings
Design of casing with all details
Providing bearings covers and seals
Gear drives are mainly used as reducer which may be made in single, double or triple stages.
Single, two and three stage reducer may appear with its shafts in parallel, also two stages with
power bifurcation or with coaxial input and output shafts. With axes inclined at right angles for
bevel gear or combination of bevel and spur gears. Worm and gear drive with the worm placed
horizontally below or above the worm gear or with the worm placed in vertical position.
Combinations of double worm and wheel reducer or spur gear and worm wheel drive are also
common gear drive type.
Gearboxes are used in almost every industry right from power to marine, and also include
agriculture, textile, automobiles, aerospace, shipping etc. There are different types of gearboxes
available for varying uses. These gearboxes are constructed from a variety of materials
depending on their end use and the kind of industry they are being used in. The product has
numerous industrial applications for providing high torque and smooth speed reductions. These
gearboxes are also manufactured keeping certain specifications in mind, which will also vary
depending on the application.
A gearbox, also known as a gear case or gear head, is a gear or a hydraulic system responsible
for transmitting mechanical power from a prime mover (an engine or electric motor) into some
form of useful output. It is referred to the metal casing in which a number of gears are sealed.
1.1.1 Advantages and Disadvantages of Gear Drives
The following are the advantages and disadvantages of the gear drive as compared to other
drives, i.e. belt, rope and chain drives:
Advantages
1. It transmits exact velocity ratio.
2. It may be used to transmit large power.
3. It may be used for small centre distances of shafts.
4. It has high efficiency.
5. It has reliable service.
6. It has compact layout.
Disadvantages
1. since the manufacture of gears require special tools and equipment, therefore it is costlier than
other drives.
1.2. Given parameters
Project-1:
Design of a Gear Box
A. Specification
i. Power [kw]:- 5KW
ii. Input Speed [rpm]: 1250
iii. Total Gear Ratio:-12.5
iv. Arrangement :-Straight drive
v. Driving Machine: Electric Motor
vi. Driven Machine:-simple grinding machine
vii. Housing Design:-Castled sheet metal
B. Main Task of the Project
1. Select the best alternative for gears carrying out preliminary calculation
2. Calculate precisely the geometry of the selected alternative so that the relative slippages
at the boarder points of the length of engagement are equalized.
3. Check the strength of the pair of gears.
4. Check the strength of the shafts and key joints.
5. Select the proper type of bearings that fulfill the requirement Lh = 12000 hrs
6. Construct the gearbox in 1:1 and trace with ink. The main fitted and calculated sizes
should be given in the drawing.
7. Check critical speeds of the shafts
8. Select an appropriate lubrication
9. Prepare a design report of the gearbox containing the assumptions, considerations,
calculations and remarks concerning the project.
1.3.Guide lines for choice the type of gear drives
Choice is made on the basis of velocity ratio and the peripheral velocity. Velocity ratios up to 8
single stage drives are preferable though these drives may be used for velocity ratios up to 25.
Two stage drives may use for velocity ratios up to 50 from 10 beyond velocity ratio of 40 three
stage drive is preferable. Straight spur gear drives between parallel shafts can be used up to 5
m/s, for greater velocities than 5 m/s helical gears must be used. Straight spur gear drives have
the advantage of no axial loading. Straight tooth bevel gears of large size are limited to
peripheral velocity of 2 m/s, for greater velocities the spiral bevel gears are used.
In single stage gear reduction, low velocity ratios must be used for straight tooth spur gears, for
high velocity ratios helical gears are recommended.
Then determine number of stages: Speed ratio i 8 is one stage type speed reducer (straight spur
gear may be used); two-stage speed reducer have speed ratio between 8 and 40, greater than 40
three-stage type speed reducer.
For a two-stage gear reducer, the distribution of the speed ratio between the two stages is as
follows:
Due to above standards my design of gear box is double stage gear box with
helical gear`
