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Design and Analysis of Differential Gearbox PDF Free
Design and Analysis of Differential Gearbox PDF Free
This project work is the bonafide work done by PRATIK PATEL, Roll No. 06 ME 43, student
of VIII semester of Mechanical Engineering Department of U. V. Patel College of Engineering,
under the guidance of Mr. S.S.PATEL SIR towards the partial fulfillment of the requirements
for the Degree of Bachelor of Technology (Mechanical) of Ganpat University,
GanpatVidyanagar.
Guide : S.S.PATEL
Internal Examiner: ____________________
External Examiner: ____________________
Head of Department: S. M. PATEL
Acknowledgement
This Project shall be incomplete if I fail to convey my heart-felt
gratitude to those people whom I received considerable support and
encouragement during this project creation. Lots of People have helped,
provided technical, commercial and also behavioral acumen at all levels
of the project and it`s my luck for get the kind of support of them. I have
no words to thanks to our special project faculty Mr. S. S. Patel sirfor
giving us his innumerous knowledge among our group of for project
partners. They are becoming as Way to take us from dark to bright
future and specially they play their important role for Motivation and to
endeavor for succeed in project creation.
Regards,
PRATIK PATEL
Abstract
My Project “DESIGN AND ANALYSIS OF DIFFERENTIAL
GEARBOX” mainly focuses on the mechanical design and analysis of
gearbox as transmit the power. I had developed this work as my
semester project with a view to get familiar with the technologies as
well as application of theories into practical work done by industries.
My project contains the design and material selection of the gearbox for
different type of vehicles also. For better efficiency, improvement of
power transmit rate is important phenomenon.
Index
Sr No. Contents Page No
Acknowledgement i.
Abstract ii.
Index iii.
List of figures iv.
List of tables v.
1 Introduction 1
2 Defination 3
2.1 Function of a System 4
2.2 Use of Gearbox 4
3 Transmission System 5
3.1 Manual Transmission 6
3.2 Automatic Transmission 7
3.3 Semi-Automatic Transmission 8
4 Gearbox Specification 9
4.1 About Gear Ratio 10
4.2 Explanation of the term 10
5 About Gearbox 11
5.1 Gearbox glossary 12
5.2 Gearbox Material 13
5.3 Types of Gearbox 13
6 Simple Differential Gearbox 15
6.1 Introduction of Simple Differential 16
Gearbox
6.2 Material Used 16
6.3 Types of Differential Gearbox 17
6.4 Use of Differential Gearbox 17
7 Design of Simple Differential Gearbox 18
7.1 Design of gears 19
7.2 Design of Bearings 24
7.3 Design of Shafts 27
8 Analysis of Gearbox 32
8.1 Analysis of Gear Shaft 33
8.2 Analysis of pinion Shaft 35
9 Bibliography 37
10 References 39
List of figure
Fig No Name Of Figure Page No
3.1.1 Manual Transmission 6
3.2.1 Automatic Transmission 7
3.3.1 Semi-Automatic Transmission 8
6.1.1 Simple Differential Gearbox 16
7.2.1 Deep Groove Ball Bearing 24
7.3.1 Basic Design of Shaft 27
7.3.2 Combine Failure of Shaft 28
7.3.3 Keyway of Shaft 28
List of Table
Table No List Of Table Page No
7.1.1 Pinion and Gear 23
7.2.1 Bearing selection 26
7.3.1 Shaft Select 31
INTRODUCTION
chapter
1. Introduction
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.
DEFINATION
chapter
2 Defination
9 A gearbox, also known as a gear case or gearhead, 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.
9 A gearbox is also a set of gears for transmitting power from one rotating shaft to another.
They are used in a wide range of industrial, automotive and home machinery application.
9 Gearheads are available in different sizes, capacities and speed ratios. Their main
function is to convert the input provided by an electric motor into an output of lower
RPM and higher torque.
2.1Functions of a Gearbox
9 A gearbox is precisely bored to control gear and shaft alignment.
9 It is used as a housing/container for gear oil.
9 It is a metal casing for protecting gears and lubricant from water, dust and other
contaminants.
2.2Use of Gearbox
¾ A variety of gearboxes find applications in a number of industries depending on the end
use. Some of the industries using gearboxes include :
¾ Agricultural
¾ Industrial
¾ Construction
¾ Mining
¾ Petrochemicals
¾ Food processing
TRANSMISSIONSYSTEM
chapter
3 Transmission System
9 There are three types of transmission system.
Manual Transmission
9 Types of Manual Transmission
¾ Synchronized Systems: This type of transmission system or gearbox does not
require synchronization with the driver while changing gears.
¾ Unsynchronized Systems: This type of transmission system or gearbox allows
free spinning of gears with their relative speeds synchronized by the driver for
avoiding clashing and grinding of gears.
9 The system is hydraulically operated and makes use of a torque converter and a set of
planetary gears.
Automatic Transmission
Semi-Automatic Transmission
chapter
4 Gearbox Specifications
9 The gear ratios can be defined as the relationship between the number of teeth on two
different gears meshed together or the circumference of two pulleys connected with a
drive belt.
9 Generally the number of teeth on a gear is also proportional to the circumference of the
gear wheel, so the bigger the wheel, the more teeth it has. Therefore the gear ratio can
also be explained as the relationship between the circumferences of both wheels.
9 The concept of gear ratio can be well explained with the help of an example as follows :
9 Suppose a smaller gear has 12 teeth, while the larger gear has 24 teeth. Therefore the
gear ratios between the smaller and the larger teeth are 12/24 or 1:2.
9 The first number in the ratio is generally the gear that power is applied to. The ratio also
means that for one revolution of the smaller gear, the larger gear has made 1/2 or 0.50
revolutions. This further implies that the larger gear turns slowly as compared to the
smaller one.
ABOUTGEARBOX
chapter
¾ Aluminum Gearbox
¾ Cast Iron Gearbox
¾ Bronze Iron Gearbox
¾ Stainless steel Gearbox
9 A variety of gearboxes are manufactured from different superior quality materials and
with different performance specifications depending on their industrial application.
These gearboxes are available in a range of capacities, sizes and speed ratios, but the
main function is to convert the input of a prime mover into an output with high torque
and low RPM. A variety of gearbox find application in a large number of industries
including agriculture, aerospace, mining, paper and pulp industry.
¾ Bevel Gearbox
¾ Helical Gearbox
¾ Planetary Gearbox
¾ Sequential Gearbox
¾ Spiral Bevel Gearbox
¾ Worm Reduction Gearbox
¾ Cycloidal Gearbox
¾ Offset Gearbox
¾ Right Angle Bevel Gearbox
¾ Shaft Mounted Gearbox
¾ Worm Gearbox
¾ Crane Duty Gearboxes
SIMPLEDIFFERENTIAL GEARBOX
chapter
9 Bevel gearboxes are special speed reducers with their shafts lying perpendicular to each
other and therefore used mainly in right-angle applications. The gearbox is a kind of
right angle gear and is suitable for a right angle solution with a low ratio. These
gearboxes save more energy as compared to worm gears and are available in varying
gearratios.
9 These gearboxes are constructed from a variety of materials. Some of the popularly used
materials are :
¾ Cast Iron
¾ Aluminum Alloy
¾ Steel
9 The ratio of a bevel gearbox can be determined by dividing the number of teeth in the
larger gear by the number of teeth in the smaller one. These gearboxes generate varying
level of torque and can also be customized to suit individual requirements.
chapter
Gear Material
For Pinion,
DirecteHardeing Steel C40
Tensile Strength σp= 620 N / mm2
Hardness = 175 BHN
For Gear,
Cast iron Grade 25
Tensile strength σg = 245 N / mm2
Hardness = 245 BHN
Gear Ratio I =
=
=3
i=
3=
Zg = 42
From the No of Teeth Select Pressure Angle
Select Module m = 5
Dg = m × z g
=210 mm
So, rg = 105 mm
Dg = m × zp
= 70 mm
So, rp = 35 mm
Center Distance A0 =
= 110.7 mm
Width b = 0.25 × A0
= 27.67 mm
tan r =
r = 71.56̊
tan γ =
γ = 18.43̊
rmp = - = 30.62 mm
rmg = - = 100.62 mm
Mtp =
= 63661.97 Nmm
Torque on Gear
Mtg =Mtp ×
= 190985.93 N.mm
Zp =
= 214.75
Zg =
= 132.85
Materials are different and hence the product of σb Y should be compared
Yp = 0.484 –
= 0.29
Yg = 0.484 –
= 0.462
Gear is Weak
Sw =
= 3775.67 N
Mtp =
Pt = 1818.91 N
Velocity, V =
= 5.49 m / s
Cv =
= 6.7050
Now calculate effective force,
Peff =
here , Ks = Multiplying factor
= Cs × Km
Peff =
= 3870 N
Check
For safety,
Sb ≥ Peff ×Fos
8474.79 ≥ 3870 N
Pinion Gear
Pitch Cone Diameter Dp = 70mm Dg = 210mm
Number of Teeth Zp = 14 Zg = 42
Module m = 5 m = 5
Pitch Angle ϒ = 18.43® ┌ = 71.56®
Cone Distance A0 = 110.7mm A0 = 110.7mm
Face Width b = 27.67 mm b = 27.67 mm
Addenda ha = m = 5mm ha = m = 5mm
Dedenda hf = 1.2m = 6mm hf = 1.2m = 6mm
Clearance c =0.2m = 1mm c =0.2m = 1mm
Table-1
7.2 Design of Bearings
9 Here I had used a two angular contact deep grew ball Bearings, one on each side are
utilized at the bevel shaft.
P=
10 × =
T = 63662 N.mm
Tangential load
Pt = = = 1818.91 N
From Pt
Axial load,
Pa = Pt ×
= 6318.33 N
Radial load,
Sinφn
Pr = Pt ×
Cosφn Sinλ + µ Cosλ
= 1732.18 N
Taking moment about the bearing,
For, Vertical Plane
Rv = 100 × 6318.34 N
= 631.83 KN
Resultant,
R = 655 KN
Here, P = Fr = R = 655 KN
=
= 900 million rev.
Basic dynamic load rating C:
C = P × (L10)1/3×Nf
= 655 × (900) 1/3× 2.5
=15.8KN
From the above value of Dynamic load calculated and the minimum acceptable diameter
(25mm).We can select the angular contact bearing 6304 from below table.
Table - 2
7.3 Design for Shaft
Design of Shaft
9. If axial thrust loads are present, they should be taken to ground through a single thrust
bearing per load direction. Do not split axial loads between thrust bearings as thermal
expansion of the shaft can overload the bearings.
10. The first natural frequency of the shaft should be at least three times the highest forcing
frequency expected in service, and preferably much more. (A factor of ten times or more
is preferred, but this is often difficult to achieve).
Combine Failure of shaft
Keyway of shaft
M1 =
M1 = 245.25 Nm
M2=
M2 = 392.4 Nm
Now,
For En 8 material
d = 214 mm.
for shaft 2,
M1 = 392.4 Nm
M2 = 145.6 Nm
=
=
=
Now,
For En 8 material
d = 75 mm.
From the table length of shaft 1 is L1 = 105 mm and length of shaft 2 is L2 = 280 mm.
Dimensions and basic capacity of single row deep groove ball bearings
ANALYSIS OF GEARBOX
chapter
8 Analysis of Gearbox
Fd = Fdx i + Fdzk
Besides the forces there is a torque acting on the shaft about y-axis.Assuming this torque
anticlockwise
T = Mtg j
Convention used
Anticlockwise + ve
Clockwise - ve
Once the forces & torques are define their position have to be decided
Rm = 100.62 i+ (-60-30.62) j+ 0 k
Rc = 0 i+ (-60-90) j+ 0 k
Rc = -150 j
For any given system to be in equilibrium,their moments about any point should be zero
Taking moment about D we get:
Rm ×Pg + Rc × Fc + T= 0
R×P=
Rm × P g =
R c × Fc =
= - 150 I - 0 j+ 150 k
Substituting we get ,
Equating we get
Fcz =
= -1247.09 N
Fcx =
= 627.455 N
Fc +Fd + Pg= 0
Fox = -388.215 N
Fcy = 719.92 N
Fdz= -832.01 N
The reaction at C & D a
Fc = 627.455 i + 719.92 j -1247.09 k
Fd = -388.215 I – 832.01 N
T = Mtp i
(assume anticlockwise direction when seen from bearing B)
Ra = -90 i
Rm = -(90 + (170 – rmg )) i + (-30.62) j
rmg = 100.62
Rm = -160.602 i – 30.62 j
Ra ×Fa + Rm × Pp + T= 0
R a × Fa =
Rm × P p =
Substituting
Fcx =
= -1203.27 N
Fa +Fb + Pp= 0
Fax = -239.24 N
Fby = 483.35 N
Fbz= -1628.32 N
chapter
9
9 (2005) About gearbox[online]. Available: http://www.gearsandgearbox.edu/
9 (2009) introduction [Online]. Available: http://en.wikipedia.org/
9 (2002)bearing design[online]. .Available: http://www.bearingdesign.org
9 (2009) shaftdesign on Wikipedia. [Online]. Available: http://en.wikipedia.org/
9 (2007) gearsrating [Online]. Available: http://everongearbox.com/
REFERENCES
chapter