2010

Alexandria University
Faculty of Engineering
Production Engineering
Department
3rd year prod. Engg.

[GEAR BOX DESIGN

CALCULATIONS]
By:
Abdel Rahman Gamal Hussein 83
Wassem Mamdouh Mohammed 171
Presented to:
Prof. Moustafa Helaly

Contents
Gears Design: ................................................................................................................................... 1
Shaft design: .................................................................................................................................... 2
Pinion shaft:................................................................................................................................. 2
Gear shaft: ................................................................................................................................... 2
Key design:....................................................................................................................................... 3
Pinion key: ................................................................................................................................... 3
Gear key:...................................................................................................................................... 3
Bearing selection: ............................................................................................................................ 4

Givens:
W = 30kW; n1 = 295rpm; n2 81.7 rpm; Desired Life 108 cycles.

Gears Design:
Based on Strength criteria:
b <= Sat * (Kl/Kr)
b =

, Using AGMA equations:

Assume:
Module = 5 mm, pressure angel = 20
Number of teeth (pinion)= 20 = Zp , then Zg = 73 , a = 1m , b = 1.25 m
(

Tpinion =
Wt =

= 971.1 N.m

= 19422 N
Dp
100
365

Pinion
Gear

Da
110
375

Db
87.5
352.5

Np/ng =Zg/Zp = 295/81.7 = 3.6177

p = 2

np/60 = 30.8 rad /sec,

g = 2

ng/60 = 8.55 rad /sec

Km = 1.6 (0 50 mm face width) ,

Ka = 1 (uniform shock),
Ks = 1 m<= 5,
Kv =

,v=

dp np / 60 = 1.5446 m/s Then Kv = .74

Kb = 1,
J= .3615 (between 55, 80 gear teeth and 20 pinion)

Substituting in the strength equation:

The right hand side for gear material
Choose carbon steel Q&T with tensile strength = 655 MPa, then the right hand side becomes:
655 * (.92/.85) = 709 MPa, hence:
The face width (F) = 32 mm, Assume 8m = 40 mm

Shaft design:
Pinion shaft:
Ft = Wt cos = 18.2507 KN
Fr = Wt sin = 6.6424 KN
Assume:
Shaft length = 150 mm
T = Ft * dp/2 = 912535.504 Nmm, M = Fr * dp/2= 332135
Then = (T * rsh)/J , J =

= 4647505/dsh^3
And b = M Y/I, I=

= 3382742.8/dsh^3
Choosing AISI 1045 for shaft material with y = 360 MPa, factor of safety=2
all = 360/4 =

solving the equation with only unknown dsh:

Dsh = 38.01 mm Assume 40 mm

Gear shaft:
Doing same calculations:
Tg = 3506.7
Wt = 19213 N

Ft = 18054 N
Fr = 6571 N
Then Dsh for gear = 55 mm
Assumed shaft length = 150 mm

Key design:
Pinion key:
Assume square key w=h:
all = 2T/dsh * 1/ W* L
w = .25 dsh = 10 mm
Assume material carbon steel tensile strength = 655 MPa
all = 655/4 = 163 MPa
Then L = 28 mm assume 50 mm

Gear key:
Assume square key w=h:
all = 2T/dsh * 1/ W* L
w = .25 dsh = 14 mm
Assume material carbon steel tensile strength = 655 MPa
all = 655/4 = 163 MPa
Then L = 52 mm assume 55 mm

Bearing selection:
Using reliability equation:
C10 =

)(

Using cylindrical roller bearing:

a = 10/3, reliability =

= .95

Ra = Rb = Wt/2 =19.422/2 = 9.711 KN (pinion) =FD

Ra = Rb = Wt/2 =19.213/2 = 9.6 KN (Gear) =FD
XD= (

Assume 30 000 hrs life

XD = 531
For Pinion:
C10 = 74 KN
Abutment = 2.5 mm, then diameter = 35 mm
Select bearing NU407
For Gear:
C10 = 74 KN
Abutment = 2.5 mm, then diameter = 50 mm
Select bearing NU2210E.TVP2