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COLLEGE OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

**MEMB333 - MACHINE DESIGN
**

SEMESTER 2 2012/2013

PROJECT TITLE : DESIGN OF TURBINE GEAR-BOX

NAME

STUDENT ID

MOHAMAD ASYRAF BIN MOHAMAD AZMI

ME087004

MUHAMMAD FADIL ARSAD BIN MOHD USOPE

ME087018

MUHAMMAD AMIN BIN ZAKARIA

ME087006

SYARIR AKRAM BIN JAMALUDDIN

ME087022

SECTION

: 01B

LECTURER

: MUHAMMAD FAIRUZ BIN ABDUL JALAL

Due Date

30/12/2012

ABSTRACT

Submitted Date

30/12/2012

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

**As the title, ‘Design of Turbine Gear-Box’, implies, this project requires us to
**

analysis and design a turbine gear box. To design the gear box, we have to follow the

specifications that have been determined for this project such as safety factor and reliability

while considering other properties such as weight, size, and design life.

Calculations and experiments involved throughout the completion of this project are

very important because they determine the value of the gearbox towards competing on the

current or local market value. The durability and the usability of the gearbox show the

identity of the gearbox compared to others in the market.

The calculations are made with the same reason which is to get the required yield and

fatigue safety factors. The main task is for us to go through different calculations to get the

best condition for the gearbox in terms of materials and cost. Days of research that we have

to go through not just to complete this project but to complete the gearbox with the best

design.

At the end of this project, we finally came out with the most desirable gearbox based

on our assumption on the material and the calculation parts. Throughout the project, we had

learnt lot of things related to our subject, MEMB333 Machine Design. Besides that, we also

learn to develop teamwork, leadership skills, research skills, and creative thinking.

The design of the turbine gear box is basically depends on the skills of each group.

For us, this design that we are proposing satisfies all the required values and the selection of

the materials and cost involved makes our design more efficient and desirable for it to

function in a best condition in a turbine system.

1

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

TABLE OF CONTENT`

Content

Page

3

4

4

4

5-16

17-22

23-24

25-28

29

30

31-35

36

1.0 Introduction

2.0 Project Title

3.0 Project Objective

4.0 Specifications

5.0 Gears Calculation

6.0 Shaft Calculation

7.0 Bearing Calculation

8.0 Keys Calculation

9.0 Mass and Costs

10.0 Discussion and Conclusion

11.0 Appendices

12.0 References

1.0 INTRODUCTION

2

This will make certain the keys will fail first in the design before any other parts. The gear box has to be designed in the most efficient way. Examples of turbine are turbofan engine on commercial aircraft and windmill. The completion of this project helps us to gain more knowledge on the gear box especially on the calculation part besides other properties to be chosen to achieve the most desirable gear box design. The shafts and the bearings need to meet a minimum safety factor of 2.0. 3 .2 for surface failure and 1. with the usage of 2 gears and also 2 shafts. The minimum safety factors required for the gears are 1. Q v based on the application on aircraft engine drive from the ‘Recommended AGMA Gear Quality Numbers for Various Applications’ table. This machine consists of shafts that create the rotational movement of the blades.5 is needed. Modern gearboxes mostly are used to reduce the speed of a prime mover output shaft by increasing the torque which means that the input shaft will rotate faster than the output. We select a rectangular configuration for the gear box. This creates mechanical advantage.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 A turbine is basically a rotary mechanical device that gains energy from a fluid flow and then converts it into a useful work. The specifications determined have to be followed to achieve the best and reliable design of the gearbox.5 for bending failure. In the calculation part. we took the value of gear quality numbers. However. for the keys. a minimum yield safety factor of 1.

FSy = 2. 1. rolling element bearings. FSy = 2.5 bending Other parts : R=90% FSf = 2.0. seals and housing.0.0 Shafts : R=90% FS =2. Co using full load conditions.0 PROJECT TITLE Design of Turbine Gear-Box.2 surface.0 Bearings check : Static failure. shafts. 3. 4.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 2.0 Bearings : R=99% FS=1.0 SPECIFICATIONS Gear box specifications: Weight : Minimal and compact Size : Minimal and compact Design life : 10 years in continuous operation Weak link design : Design the input shaft key or output shaft key to a yield factor of safety about 1.0 PROJECT OBJECTIVE To design a turbine gear-box which consists of spur gears.5 Predetermine value: Keys : R=90% Minimum FSf = 2.0 Design gears : R=90% FSf = 1. keys or press fits. FS =2.0 4 .

5 rpm The gear ratio is 1: 3. The design of the gear box is to increase the speed from the input rpm.5 in Ng = 135 teeth 3. Output gear (pinion): Diameter = 2 in Thickness = 1.612 2.5 in Np = Ng/3.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 5.0 GEARS CALCULATION Motor input = 300k watts Output speed (output shaft rotation) = 2950rpm Assumptions: 1. Input gear: Diameter = 5 in Thickness = 1.612 from the input rpm.612 = 37 teeth 5 .612 = 816. We increase it by 3. Therefore. the input speed is:2950 rpm / 3.

coarse pitch (Pd < 20) Parameter Addendum a Dedendum b Working depth Whole depth Circular tooth thickness Fillet radius-basic rack Minimum basic clearance Minimum width of top land Clearance(shave or ground Equation .050 0. 4th Edition) Torque: P = Tω P = 300k watts = 402. 719 (Machine design textbook.3 hp 5.262 0.350/Pd values 0.167 0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 Gear tooth specifications: Pd = 6 Therefore.042 0.300/Pd 0.208 0.375 0.333 0.000/Pd 2.250/Pd 0.000/Pd 1.16 in = 22.058 teeth) Table 1: Value of Pd for Each Parameter Assumed pinion Np = 100.250/Pd 0.250/Pd 2. Pd = 6 1. then the pitch diameter for that combinations is dp = Np Pd = 37 6 dg = Ng Pd = 135 6 = 6. pg.571/Pd 0.1 Input Gear 6 .5 in 6 is a standard pitch by referred from table 12-2. gear Ng = 36 .250/Pd 1.042 0.

50 rad /sec ( 402.25 in = 1380.50 rad/sec T = P/ω = 6600 lb.in Wtmax = Tmax / rg = 31054.25 in = 1380.in Tm = Tmax + Tmin / 2 = 15527.37 lb in /11.∈¿ sec ) hp 85.in Tmin = 0 lb.in /11.in Tmax = 31054.5 rpm) x 2 π 60 = 85.2 Output Gear (Pinion) 7 MEMB 333 .[DESIGN OF TURBINE GEAR-BOX] ω = 816.3 hp ) ( = 31054.74 lb.74 lb.25 in = 2760.37 lb.74 lb.37 lb in /11.37 lb.5 rpm = (816.in Ta = Tmax – Tmin / 2 = 15527.21 lb 5.42 lb Wtmin = Tmin / rg =0 Wta = 15527.21 lb Wtm = 15527.

29 lb Wta =1380. 08 in = 1395.42 lb Wtmax = 2790.21 lb Wtm = 1395.29 lb 8 . For gear part For pinion part Wtmax = 2760.92 rad/sec T = P/ω = 6600 lb.in / 3.52 lb. to calculate the forces that exist on each part of the system.[DESIGN OF TURBINE GEAR-BOX] ω = 2950 rpm = (2950 rpm) x 2 π 60 MEMB 333 = 308.52 lb.92rad / sec ( 402.∈¿ sec ) hp 308.59 lb Wtmin = Tmin / rp =0 Wta = 4297.04 lb.in Tmax = 8595.08 in = 2790.59 lb Wtm = 1380.29 lb By taking the pressure angle as 25 and using the formula W = Wt / cos (25). 08 in = 1395.in /3.21 lb Wta = 1395.in / 3.3 hp ) ( = 8595.52 lb.in Tmin = 0 Ta = Tmax – Tmin / 2 = 4297.04 lb.52 lb.04 lb.in Wtmax = Tmax / rp = 8595.in Tm = Tmax + Tmin / 2 = 4297.29 lb Wtm = 4297.

there is only one part of calculation that is input gear-pinion output since it is the single stage gear box.42 ft/min A h) Velocity factor. Kvp = Cvp = A+ √ Vtp ] ^B ¿ = 0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 5. Km .16/2*12) (816. Pd .58 ft/min g) Pitch-line Velocity. F = 12/ Pd =2 d) Assume AGMA Quality Factor is for aircraft engine drive. J . Assumption: 1. Vtg = (dg/2) *ωg = (22.397 A = 83. B = ((12 – Qv) ^ (2/3) ) / 4 A = 50+ 56(1-B) f) Pitch-line Velocity.42 lb b) Pd = 6 c) Face width factor.397 = 0. Kv.768 .5 rpm *2 π ) = 4757. 2. so Qv = 10 e) The dynamic load factor.5 rpm *2 π ) = 4809. The bending stress equation for stress: σ b = Wt . Kvg = Cvg = A+ √ Vt g ] ^B ¿ = 0. Ks .547^0.397 = 0.79 A i) Velocity factor. Ka . The stresses that will be analyses are the bending stress and the surfaces stress.79 9 B = 0. Ki F .547^0.5/2*12) (816. Ka . Vtp = (dp/2) *ωg = (6. Kv a) Wt = 2760.3 Overall Gear Calculation For the gear calculation. Kb.

543 Jp = 0.79 = 34780.03088 Mpsi σ bp = = Wt . Ki F .59∗6∗1∗1.035M psi 10 . J for 25ᵒ.6∗1∗1∗1) 2∗0. Ka . Kv (2790. Km .6 (Refer to Table 12-16) Ka = 1. Kv (2760.79 = 30887.9 psi = 0.6∗1∗1∗1) 2∗0. (assume) F. Ks .48 psi = 0. Kb F . J .543∗0. Km . Ka .0 (due to uniform load) (Refer to Table 12-17) k) Assume bending geometry factor. Ks . Face width <= 2 Km =1.4875 l) Taking/assume: Ks = 1 Kb = 1 KI =1 m) The bending stress for pinion and gear: σ bg = = Wt . full depth teeth with HPSTC loading: Jg = 0. Pd . Ka .4875∗0.42∗6∗1∗1. Pd .[DESIGN OF TURBINE GEAR-BOX] MEMB 333 j) Mounting Factor. J . Ka .

5∗0.(assume the material for the pinion and gear made of steel so Ep = Eg = 30E6 psi)( Vp = Vp = 0. Cf ( 2 ) ) F .28 )(from table 12-18) Elastic coefficient for steel. Ca.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 3.119 Mpsi 11 .7 = 1.Cm.7 + 1/1.25 cos 25) ²] ^ 0.08 + 11.Cs .5) = 0.79∗0.(11.7 ρ2 = C sin . Assume Cf = 1 as the gear and pinion are made by conventional method σ cig = Cp( = 2276[ 1 Wt .Cv.25) sin 25 – 4. Cf = 1 (From equation 12. Cm .5 – [( π /6)* cos 25] = 4.ρ1 = (rp + rg) sin .69 psi = 0.6*1*1) / ( 2∗22.(rg cos ∅ )²) ^ (1/2) – (( π /Pd ¿ *cos ) = [(11.dg . Cp = 2276 Surface factor. I 2760.Ks as define for the bending stress equation.42 (1 /2) *1*1.42 1/ ρ ¿ ∅¿ /¿ I = (cos 1 + 1/ρ2)* dg) = (cos 25) / ((1/4.Km.42)*22.Cv .23) (Well finished gear by conventional method) b) The surface geometry factor I can be calculated: Gear (Idle) ρ1 = ((rg + (1/Pd)² .ρ1 = (3.Cs are equal respectively to Ka.25) + (1/6)) ² .Kv.045 c) Surface stress in pinion-gear mesh: Assume Ca. Surface Stress: a) The surface stress for pinion-gear: .045 ¿ ¿ ¿ = 119589.

6*1*1) / ( 2∗6.183 = 4.59 (1/ 2) *1*1.130 Mpsi 12 .(rp cos ∅ )²) ^ (1/2) – (( π /Pd ¿ *cos ) = [(3.87)*6.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 Pinion (Idle) ρ1 = ((rp + (1/Pd)² .79∗0.183 + 1/4.Cs . Ca.87 I = (cos 1/ ρ ¿ ∅¿ / ¿ 1 + 1/ρ2)* dp) = (cos 25) / ((1/1. Cm .14 d) Surface stress in pinion-gear mesh: assume Ca.(3.dp .Km.Cv.ρ1 = (3.16∗0. assume Cf = 1 as the gear and pinion are made by conventional method σ cip = Cp( = 2276[ 1 Wt .Cs are equal respectively to Ka.16) = 0.87 psi = 0.25) sin 25 – 1. Cv .08) + (1/6)) ² .ρ1 = (rp + rg) sin .Kv.183 ρ2 = C sin .08 cos 25) ²] ^ 0.Cm. Cf ( 2 ) ) F .08 + 11. I 2790.14 ¿ ¿ ¿ = 130285.Ks as define for the bending sterss equation.5 – [( π /6)* cos 25] = 1.

0.126HB2 ----. N = (2950rpm)(60 min/hr)(8760hr/yr) (10 year) = 1.0517 Mpsi ii) Number of cycles:Assume 10 year life in continuous operation.(using grade 2 maximum) = 6235 + 174(350) .[DESIGN OF TURBINE GEAR-BOX] MEMB 333 4.0323) = 0.55E10) ^ (-0.789 iv) Operate at specified temperature Kt = 1 v) Realibility =90% Kr = 0.047989 Mpsi For pinion 13 . through hardened to 350HB The uncorrected bending fatigue strength: Sfb’ = 6235 + 174HB .85 vi) Corrected surface fatigue strength:Sfb = (KL /( Kt *Kr)) * Sfb’ = 0.6831(1.55E10 cycles iii) The value of KL KL = 1.126(350)2 = 51700 psi = 0.0. Calculate corrected bending fatigue strength: For gear i) assume using AGMA class A4 steel.

(using grade 2 maximum) = 6235 + 174(400) . N = (2950rpm)(60 min/hr)(8760hr/yr) (10 year) = 1.85 vi) Corrected surface fatigue strength:Sfb = (KL /( Kt *Kr)) * Sfb’ = 0.6831(1.0.55E10) ^ (-0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 i) assume using AGMA class A5 steel.55E10 cycles iii) The value of KL KL = 1. through hardened to 400HB The uncorrected bending fatigue strength: Sfb’ = 6235 + 174HB .0.05198 Mpsi 14 .126HB2 ----.056 Mpsi ii) Number of cycles: Assume 10 year life in continuous operation.0323) = 0.789 iv) Operate at specified temperature Kt = 1 v) Realibility =90% Kr = 0.126(400)2 = 55675 psi = 0.

056) = 0.158 Mpsi ii) CL =2. Calculate corrected surface fatigue strength: For gear :i) For an AGMA A4 steel.Cr))* Sfc’ = [ 0.55E10) ^ (-0.(using grade 2 maximum) = 27000 + 364(400) = 172600 psi = 0. through hardened to 400 HB Sfc’ = 27000 + 364HB ---.158 Mpsi = 0.466 (1.(using grade 2 maximum) = 27000 + 364(360) = 158040 psi = 0.85)] * 0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 5.85 v) CH = 1 (assume gear and pinion of the same hardness material) vi) The corrected surface fatigue strength: Sfc = ((CL.CH )/(CT.663x1/(1x0.173 Mpsi 15 .663 iii) Ct =Kt=1 iv) Cr=Kr=0.123 Mpsi For pinion :i) For an AGMA A5 steel. through hardened to 360 HB Sfc’ = 27000 + 364HB ---.

051981Mpsi / 0.466 (1.034780M psi Nb pinion = 1.03088 Mpsi Nb gear = 1.13 16 .85 v) CH = 1 (assume gear and pinion of the same hardness material) vi) The corrected surface fatigue strength: Sfc = ((CL.85)] * 0.663x1/(1x0.119 Mpsi)² Nc idler-gear = 1.CH )/(CT.047989 Mpsi / 0.Cr))* Sfc’ = [ 0.056) = 0.130285 Mpsi)² Nc idler-gear = 1. pinion and surface gear-pinion: i) FSgear = Sfb / σ bg = 0.663 iii) Ct =Kt=1 iv) Cr=Kr=0.123 Mpsi/ 0.173 Mpsi = 0.1 iv) FSidler-pinion = (Sfc / σ ci-p)² = (0.55 ii) FSpinion = Sfb / σ bp = 0.55E10) ^ (-0.5 iii) FSidler-gear = (Sfc / σ ci-g)² = (0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 ii) CL =2.1382 Mpsi/ 0.1382 Mpsi 6.Factor of safety for gear.

(Sut)b = 2. low-carbon.6) Load Size Surface : : Cload = 1 Csize = 1 : Refer Table 6-3: A = 2.7 ( 64 )-0.0 SHAFT CALCULATION In this shaft analysis. Sf’ = 24111. Csize .7 b = -0. Creliab . Chapter 6. In the same time. We use SAE 1018 Cold-Rolled Steel because it inexpensize.36 kpsi 17 .265 (bending load) (machined cold rolled) Temperature : Realibility : Csurface = A. 4th Edition by Robert L.84 Ctemp = 1 Creliab = 0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 6.897 (R = 90 %) Refer Table 6-4 Modified Endurance Limit: Sf = Cload . Csurf . cold-rolled steel Sut = 64 kpsi Sy = 54 kpsi Uncorrected fatigue strength Steels Se’= 0.265 = 0.5(64000) = 32000 kpsi (Refer to book of Machine Design. got 2 shafts needed to be analysis which are input shaft and the output shaft. we assume that both shafts using the same material thus they will have the same Ultimate tensile strength (Sut) and yield strength (Sy). Norton. Ctemp .5Sut = 0.

∈¿ 4 Where minimum moment is zero because 4. minimum force at input shaft is 0 lb because the minimum force is 0. 2. Finding M mean and M m= M max + M min 2 M a= M max−M min 2 M m=M a= Fmin M alternating 198.1 Analysis of Input Shaft 1. Maximum and minimum force at input shaft Ft = max T max rg Where T max is the maximum torque exert on the input shaft through gear which gives Ft = 186. Maximum and minimum moment Assume gears will centered between the simply supported bearings set 4 in apart.399 lb 3.399) =198.434 = cos ∅ cos ( 20) max is taken from last calculation gives Fmax =¿ 198.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 6. Maximum and minimum resultant force Fmax = Ft Where max Ft 186.399 lb . M max= l x F max 4 M max= (4 x 198. Therefore. .434 lb max Where.399−0 2 18 is 0. length of shaft is 4 in.

5 Sut S è =0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 M m=M a=99. Ctemp =1 since no temperature given .434−0 2 T a=T m=93. Calculating uncorrected endurance strength.84 )( 1 ) ( 0.897 ) (32000) S e =24111. Finding bending and torsional stress in the keyway K f =1+q ( K t−1) 19 Sy = 54 . S e =( 1 ) (1 )( 0.∈¿ 6. S è S è =0.∈¿ 5. Finding T m and T a T m= T a= T max + T min 2 T max −T min 2 T a=T m= 186.5(64000) S è =32000 psi Where the material used is SAE 1018 cold-rolled steel with S ut = 64 kpsi and kpsi gives S è =32000 psi ¿ C surf Ctemp Creliab S è S e=C load C ¿ Where: - Cload =1 for bending∧torsion . ¿ ¿ 1 since we dont know t h e ¿ ¿ C¿ C surf =0.897 for 90 reliability . Creliab =0.1995lb .217 lb .84 .36 psi 7.

15)(93.15 8.00 K f =1+q ( K t−1) K f =1+0.50.57 ( 3.36 64000 ¿ √ 1 √¿ 3 32( 2.5) ¿ π ¿ dinput =¿ d input =¿ 0.5 ( 3.1995) ) ) + ((2.15)(93.57 for assumed notch radius of 0.1995) ) ¿ 3 ¿ 2+ ((2.6872 in 20 .0−1 ) K fs =K fsm=2.01in. Finding input diameter N sf =2.217))2 4 ¿ 2 3 2 ( ( ¿(99.5 Assume ( kf M a) ¿ 3 ¿ 2+ (k fs T a )2 4 2 3 2 k fm M m ) + ( k fsm T m ) ( (¿ ¿ ¿) 4 + Sf S ut ¿ √ 1 3 √¿ 32 N sf ¿ π ¿ d input =¿ 2 ( ¿(99. Therefore it will gives K f =1+q ( K t−1) K f =1+0.217) ) ¿) (2 4 ¿ + 24111.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 Where notch sensitivity of the material is found from Figure 6-36 and for bending is q = 0. and for torsion q = 0.0−1 ) K f =K fm=2.

Finding output diameter 21 .2868 lb.2 Analysis of Output Shaft 1.217 lb. but its torque is only 40 % of the output shafts.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 6.434−0 2 Ta=Tm=93. The mean and alternating torques on it are : T m= T a= T max + T min 2 T max −T min 2 T a=T m= 186. The output shaft has the same mean and alternating bending moments as the input shaft.∈¿ 2.∈¿ x 40% = 37.

1995(¿) ) ¿ 3 2 ¿ 2+ ((2.2868) ) ¿ ¿ 4 64000 ¿ ¿ √¿ ¿ 32(2.6105 in 22 MEMB 333 .[DESIGN OF TURBINE GEAR-BOX] ( kf M a) ¿ 3 ¿ 2+ (k fs T a )2 4 2 3 2 k fm M m ) + ( k fsm T m ) ( (¿ ¿ ¿) 4 + Sf S ut ¿ √ 1 3 √¿ 32 N sf ¿ π ¿ d output =¿ 2 ( ¿( 99.1995) ) ( ¿ 3 ¿ 2+ (( 2.5) ¿ π ¿ d output =¿ ) d output =¿ 0.2868))2 4 ¿ 2 ¿ ( 99.15)(37.15)(37.

0219)(11.217)(4) (0.2868)(4) ( 0.2 Output shaft (deflection) 4 Where.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 6.0136)(11. θ= (93.7 M ) θ=1.6872 ) 32 4 = π ( 0. J for solid shaft is J = θ= πd 32 (37.0136 ¿4 .3.3 Analysis of Shaft Deflection 1.373 x 10 ∈¿ 23 = 0.3.7 M ) −4 θ=9.6105 ) 32 4 = 0. J for solid shaft is J = πd 32 = π ( 0.0219 ¿4 l = length of shaft T= torque experience at shaft G for steel carbon = 11.455 x 10−3 ¿ 4 6.7Mpsi Therefore. Input shaft (deflection) Angular deflection in ∅= (radian) Tl GJ 4 Where.

l = 0. Input bearing: d shaft =0.0472 in Width = 0.6085lb Lshaft 4 K R =0.7874 in Outer diameter = 2.6085 ¿ ¿ L10=¿ 3 3 LP =K R L10=0.6872 in) = 0.911 x 10 cycles Assumed l/d = 0.21(71.434 = =46.[DESIGN OF TURBINE GEAR-BOX] 7.0 BEARING CALCULATION 1.21( Reliability 99 ) Co P ¿ ¿ 1930 46.6872∈¿ bearing number=6304 C=3000 lb C o=1930 lb P= T 186.5906 in 24 MEMB 333 .75 So bearing length.5154 in Refer Figure 11-23(Textbook Machine Design 4th Edition pg. 688) Bearing number 6304 Bore/Internal diameter = 0.75(0.003 x 10 )=14.

21(2.164 x 104 cycles Assumed l/d = 0.217 = =23.6693 in Outer diameter = 1.75 So bearing length.5118 in 25 MEMB 333 .75( 0. 688) Bearing number 6303 Bore/Internal diameter = 0. l = 0.8504 in Width = 0.3043 ¿ ¿ L10=¿ LP =K R L10=0.459 x 10 5)=5. Output bearing: d shaft =0.6105 in) = 0.3043 lb Lshaft 4 K R =0.21( Reliability 99 ) Co P ¿ ¿ 1460 23.[DESIGN OF TURBINE GEAR-BOX] 2.6105∈¿ bearing number =6303 C=2320 lb C o=1460 lb P= T 93.4579 in Refer Figure 11-23(Textbook Machine Design 4th Edition pg.

55) ²=4103.0 KEYS CALCULATION 1.295 lb r 0.295 = =¿ 2901.217 lb.411 psi From this we achieved the fatigue safety factor: 26 . in Diameter = 0.5) Fm 271. in Fm = Fa= Ta 93.55)²=4103. Assumed key length = 0.217 lb.217 = =271.5 in: τa= τm= Fa 271.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 8.411 psi σ ' m=√ σ x2 +σ y 2−σ x 2 σ y2 +3 τ 2 xy= √ 3(2901.55 psi A s h ear ( 0.187 ) (0.5) Von Mises equivalent stresses for each component: σ ' a= √σ x 2 +σ y 2−σ x 2 σ y 2 +3 τ 2 xy=√ 3(2901.3436 Assumption X inch of the alternating and mean shear stress components Based on Table 10-2 (Textbook).187 ) (0.6872 in Alternating torque = 93. 1st Shaft (gear shaft) Mean torque = 93.295 = =2901.55 psi A s h ear ( 0.

010 = =0.268 Maximum force of the key σ ' max= Fm+ Fa 271. To find the safety factor. Where q= 1 1+ √ a √r = 0.5 K ts=2.7 K f =1+q ( K t−1) .295+271. r 0.5) Safety factor for bearing failure Ns= Sy 54000 = =6. Kts. first.0146 d 0.22 σmax 8681.7−1 )=1.295 = =8681.5 ( 2.6872 K t=2.36 64000 =¿ MEMB 333 4.125(0.44 psi A bearing 0.44 All the assumption is for worst case scenario.[DESIGN OF TURBINE GEAR-BOX] Nf ¿ 1 σ'a σ'm + Se Sut = 1 4103.411 + 24111.411 4103. we must find the r /d ratios for this certain point and get the value of Kt.5 (bending) Kf = 1.75 K ts −1 ) K fs =1+q ¿ K fs =1+0.010 inch. We assumed a radius on the end mill is 0.8 5 27 . from Figure 10-16.

287 = =122. in Fa= Ta 37.287 lb.152 lb r 0. 2nd Shaft (pinion shaft) Mean torque = 37.152 τm= = ¿ A s h ear Von Mises equivalent stresses for each component.187 ) (0.152lb r 0.819 psi 28 .30525 Fm= Tm 37.187 ¿ 0.5 = inch: τa= Fa 122.5 (¿) ¿ Fm 122.6105 inch Alternating torque = 37.13 2.439 psi A s h ear ( 0.5) 0.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 K fsm =K fs=¿ 1. σ ' a= √σ x 2 +σ y 2−σ x 2 σ y 2 +3 τ 2 xy=√ 3(1306.30525 Assumption X inch of the alternating and mean shear stress components Assumed key length 0.439)²=2262.287 lb.85 { [( 32 Nf d 1= π Ma 2 3 Tm Kf + K fsm Sf 4 Sy ) ( 1/ 3 2 1 /2 )] } Nf =¿ 4.287 = =122. in Diameter = 0.152 = =¿ 1306.

819 psi From this we achieved the fatigue safety factor: Nf ¿ 1 = σ'a σ'm + Se Sut 1 2262.75 K f =1+q ( K t−1) .152+ 122.864 All the assumption are for worst case scenario.010 = =0. To find the safety factor.010 inch. we first must find the r /d ratios for this certain point and get the value of Kt .675 29 .152 = =3908.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 σ ' m=√ σ x2 +σ y 2−σ x 2 σ y2 +3 τ 2 xy= √ 3(1306.819 2262. We assumed a radius on the end mill is 0.5 (bending) Kf = 1.439)²=2262. r 0. Where q= 1 1+ √a √r = 0.819 + 24111.6105 K t=2.016 d 0.74 Maximum force of the key σmax = Fm+ Fa 122.36 64000 =¿ 7.35 K ts=2.815 σmax 3908.5) Safety factor for bearing failure Ns= Sy 54000 = =13.125 ) (0. Kts .from Figure 10-16.864 psi A bearing ( 0.

10 Shafts (Keys and Bearings) 4.[DESIGN OF TURBINE GEAR-BOX] MEMB 333 K ts −1 ) K fs =1+q ¿ K fs =1+0. the total costs reach about RM 200.875 { [( 32 Nf d 2= π Ma 2 3 Tm Kf + K fsm Sf 4 Sy ) ( 1/ 3 2 1 /2 )] } Nf =¿ 3. the total mass of the gearbox is around 39.00 Tot a l 39. The raw materials cost was about RM 24.20 (RM) 7.75−1 )=1.86 2.06 kg.51 Parts Tab l e 2 : M a s s a n d C o s t s o f E a c h P a r t Hence.0 MASS AND COSTS Mass Costs Gears (kg) 14.41 Housing 20 15. 30 .51.875 K fsm =K fs=¿ 1.5 ( 2. Including the workmanship.00.199 9.06 24.

keys and others by referring the method shown in the textbook. Upon the completion of this project.0 DISCUSSION AND CONCLUSION From this ‘Design of Turbine Gear-Box’ project. The gear ratio is 1:3. Pd is assumed 6. Ng. bearing. shaft. through hardened. In a turbine drive 300kW power is transmitted using pair of spur gear.5inches with the amount of 135 for the number of teeth. Ng is 37. The design of this gearbox is all based on the source from the textbook and internet. The diameter and thickness of the input gear are 5inches and 1. As for the pinion. through hardened type of material is used. The pinion speed is 2950rpm and that of the gear is about 816. The material used for the gear is AGMA A4 steel. The diametral pitch. For the output gear (pinion).[DESIGN OF TURBINE GEAR-BOX] MEMB 333 10. The material that we used and the cost that is required for this 31 . the diameter and thickness are 2inches and 1.5 inches while the number of teeth. AGMA class A5 steel.612. we manage to design the turbine gearbox which meets the predetermined value.5rpm. we have calculated a lot of parameter to design each component of turbine gearbox such as spur gear.

0 APPENDICES Project Drawing: Diagram 1:Spur Gear 32 .[DESIGN OF TURBINE GEAR-BOX] MEMB 333 turbine gearbox have been discussed properly and the target is to achieve the most efficiency and desirable turbine gearbox design that we can create. 11.

[DESIGN OF TURBINE GEAR-BOX] Diagram 2:Input Shaft Diagram 3: Output Shaft 33 MEMB 333 .

[DESIGN OF TURBINE GEAR-BOX] MEMB 333 Diagram 4: Pinion 1 Diagram 5: Outside view of the Table Saw Gear Box 34 .

Spur Gear and Key 35 MEMB 333 .[DESIGN OF TURBINE GEAR-BOX] Diagram 6: Bearing.

[DESIGN OF TURBINE GEAR-BOX] Diagram 7: Gearbox in Windmill turbine 36 MEMB 333 .

[DESIGN OF TURBINE GEAR-BOX] MEMB 333 12.motiva. Internet: http://en. 4th Edition 2.fi/myllarin_tuulivoima/windpower %20web/en/tour/wtrb/powtrain.htm http://machinedesign.wikipedia.org/wiki/Accessory_drive http://www.org/wiki/Turbine http://en. An Integrated Approach.wikipedia.0 REFERENCES 1.com/article/shaft-keys-that-reduce-manufacturing-costs-andmachine-downtime-0924 37 . Textbook: Machine Design.org/wiki/Transmission_(mechanics) http://en.wikipedia.

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