MIT ACADEMY OF ENGINEERING

School of Mechanical & Civil Engineering

DESIGN OF TRANSMISSION SYSTEM

DESIGN REPORT
SEM VI
AY: 2021-22

Div: TY B Batch: B3 Date: 25/04/2022

Sr No Roll No Seat No Name of Students Sign

1 3252 T219040 VEDANT GHODKI

2 3256 T219067 SANKET PANDE

3 3257 T219087 SUMEDH PATIL

4 3262 T219179 YASH SUJGURE

5 3263 T219182 VYANKATESH MANKAR

6. 3267 T219144 SUSHANT INGAWALE

7. 3272 T219003 JATTIEN KUMAR SHARMA

Prof. Amit Belvekar Dr. Prafulla Hatte

Sign of Faculty Signature of Dean

Subject Teacher SMCE

 Design Report
Problem Statement
Design a 2 Stage Helical- Bevel Gearbox Which is used in Airport luggage- Conveyors
System where input speed is 1440 rpm , output- speed is 175 rpm , power is 5 H.P
i] i/p speed = 1440 rpm
ii] o/p speed = 175 rpm

Parts of gearbox to Design

1. Helical Gear pair
2. Bevel Gear pair
3. Shaft
4. Keys
5. Bearings
6. Casing Design

Applications of Airport Luggage- Conveyors System

i] Baggage handling systems can help improve their baggage handling efficiency and overall
service towards airlines and passengers.
ii] The Conveyors must integrate perfectly with all other checking or handling of the airport
system.

Given data: Helical-Bevel two stage gearbox

i] i/p shaft speed = 1440 rpm
ii] o/p shaft speed = 175 rpm
iii] power rating = 5 H.P

Selecting of stage of gearbox :-

𝑖
𝑠𝑝𝑒𝑒𝑑
′ 𝑝
𝑖 =𝑜
𝑠𝑝𝑒𝑒𝑑
𝑝
1440
𝑖′ = = 8.228
175
(Ref. page No 671 (V.B Bhandari)
In single stage gearbox reduction ratio should not exceed 6:1
𝑖 = 2√𝑖 ′ = 2√8.22 = 2.8685

Selection of material
i<4 ∴ 𝑝𝑖𝑛𝑖𝑜𝑛 C45. (Ref. page No 8.4 DDB)
Gear C35 Mn75

Properties of Materials

Pinion(C45) :- Hardened and Tempered

𝑆𝑢𝑡 = 650 𝑁/𝑚𝑚2
𝑆𝑦𝑡 = 380 𝑁/𝑚𝑚2
Wheel (C35Mn75): Hardened and Tempered
𝑆𝑢𝑡 = 700 𝑁/𝑚𝑚2
𝑆𝑦𝑡 = 450 𝑁/𝑚𝑚2

Hardness
C45 => BHN = 3000 Ref. page No 1.9 (Design Data Book)
C35Mn75 => BHN =>330
H.B pinion = H.B gear ≥ 30 (page No 1.9 and 1.3 from design data book)
 Helical Gear Pair Design

As Gear Ratio (G) = 2.868

𝑛𝑝
𝐺=
𝑛𝑔
1440
2.868 =
𝑛𝑔

𝑛𝑔 = 502.0045 rpm

Intermediate Shaft Speed= 502 rpm

∴ 𝐴𝑠𝑠𝑢𝑚𝑒 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑛 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑝𝑖𝑛𝑖𝑜𝑛 𝑍𝑝 = 18

𝑍𝑔
𝐺=
𝑍𝑝
𝑍𝑔
2.8685 =
18
𝑍𝑔 = 51.633 ~ 52

(𝑁𝑜 𝑜𝑓 𝑡𝑒𝑒𝑡ℎ 𝑜𝑓 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑔𝑒𝑎𝑟)

𝑍𝑔 52 52
𝑍′𝑔 = 3
= 3
= = 69.86~70
𝑐𝑜𝑠 𝛼 𝑐𝑜𝑠 25 0.74443
𝑍𝑝 𝑍𝑝 18
𝑍′𝑝 = 3
= 3
= = 24.179
𝑐𝑜𝑠 𝛼 𝑐𝑜𝑠 (25) 0.74443

Step 1 : Beam strength

(𝑆𝑢𝑡) 𝑃 650
𝜎𝑏𝑝 = = = 216.67 𝑁/𝑚𝑚2
3 3
(𝑆𝑢𝑡) 𝑔 700
𝜎𝑏𝑔 = = = 233.34 𝑁/𝑚𝑚2
3 3
2.87
𝑌′𝑝 = 0.484 − = 0.3653
𝑍𝑝
2.87
𝑌′𝑔 = 0.484 − = 0.4429
𝑍𝑔

𝜎𝑏𝑝 ∗ 𝑌′𝑝 = 216.67 ∗ 0.3653 = 79.1495

𝜎𝑏𝑔 ∗ 𝑌′𝑔 = 233.34 ∗ 0.4429 = 103.3413

𝜎𝑏𝑝 ∗ 𝑌′𝑝 < 𝜎𝑏𝑔 ∗ 𝑌′𝑔

Therefore, Pinion is weaker in Bending

𝐹𝑏 = 𝜎𝑏𝑝 ∗ 𝑌′𝑝 ∗ 𝒎𝒏 ∗ 𝑏 = 216.67 ∗ 0.3653 ∗ 𝒎𝒏 ∗ 10𝒎𝒏

𝐹𝑏 = 791.4955 𝒎𝟐𝒏

Step 2. Wear Strength

𝒎𝒏 ∗ 𝟏𝟖
𝒅𝒑 = 𝒎𝒕 ∗ 𝒁𝒑 = = 𝟏𝟗. 𝟖𝟔𝟎𝟖 𝒎𝒏
𝒄𝒐𝒔 𝜳
2𝑍𝑔 2 ∗ 52
𝑄 = = = 1.4857
𝑍𝑔 + 𝑍𝑝 52 + 18

𝐵𝐻𝑁 2 330 2
𝐾 = 0.16 ( ) = 0.16 ( ) = 1.7424
100 100
𝒅𝒑 ∗ 𝒃 ∗ 𝑸 ∗ 𝑲 𝟏𝟗. 𝟖𝟔𝟎𝟖𝒎𝒏 ∗ 𝟏𝟎𝒎𝒏 ∗ 𝟏. 𝟒𝟑𝟓𝟕 ∗ 𝟏. 𝟕𝟒𝟐𝟒
𝑭𝒘 = 𝟐
=
𝒄𝒐𝒔 𝜳 𝒄𝒐𝒔𝟐 (𝟐𝟓)

𝑭𝒘 = 𝟔𝟐𝟓. 𝟗𝟐𝟕𝟖𝒎𝟐𝒏

Step 3. Beam Vs Wear Strength

𝐹𝑏 = 791.4955 𝒎𝟐𝒏

𝑭𝒘 = 𝟔𝟐𝟓. 𝟗𝟐𝟕𝟖𝒎𝟐𝒏

∴ 𝐹𝑏 > 𝐹𝑤
Gear pair is weaker in pitting.

Step 4. Preliminary Estimation

Tangential force (Ft),

𝜋𝑑𝑛 𝜋 ∗ 19.0868 𝑀𝑛 ∗ 1440
V = 60000 = = 1.49 Mn
60000
 𝑃 3.7285 ∗103 2502.34
Ft = 𝑉 = =
1.49 𝑀𝑛 𝑀𝑛

Maximum Tangential force,

Ft max = Ka * Km * Ft

1.3 ∗1.1 ∗ 2502.34 3578.3462

Ft max = =
𝑀𝑛 𝑀𝑛

𝑘𝑎 ∗ 𝑘𝑚 ∗ 𝐹𝑡 1.3 ∗ 1.1∗ 2502.34

Feff = =
𝑘𝑣 𝐾𝑣∗ 𝑀𝑛

5.6
Where , Kv = 5.6 +
√1.49 𝑀𝑛

Therefore,
1.5 ∗ 3578.3462 5.6 + √1.49 𝑀𝑛
626.9278 Mn^2 = [ ]
𝑀𝑛 5.6

Mn = 2.24 ≈ 3

Step 5. Precise Estimation

𝑏 = 10 ∗ 3 = 30 𝑚𝑚
3019.1544
𝐹𝑡𝑚𝑎𝑥 = = 1006.3848 𝑁
3

𝐹𝑤 = 520 ∗ 32 = 7663.4811 𝑁

𝑑𝑝 = 𝑚 ∗ 𝑍𝑝 = 18 ∗ 3 = 54 𝑚𝑚

𝑑𝑔 = 𝑚 ∗ 𝑍𝑔 = 52 ∗ 3 = 156 𝑚𝑚

𝑉 = 1.3571 ∗ 3 = 4.0713 𝑚/𝑠

𝑒 = 𝑒𝑝 + 𝑒𝑔 = 15.2093 + 16.2653 = 31.4746 𝜇𝑚

𝑐 = 11400𝑒 = 11400 ∗ 31.4746 = 358.8115 𝑚𝑚

 21𝑉( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 ) 21 ∗ 4.0713(27.5136 ∗ 358.8115 + 1006.3848)
𝐹𝑑 = =
21𝑉 + √( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 ) 21 ∗ 4.0713 + √(27.5136 ∗ 358.8115 + 1006.3848)

𝐹𝑑 = 4900.4235 𝑁

𝐹𝑒𝑓𝑓 = 𝐹𝑑 + 𝐹𝑡𝑚𝑎𝑥 = 5906.8083 𝑁

𝐹𝑤
𝑁𝑓𝑐𝑎𝑙 = = 0.6212
𝐹𝑒𝑓𝑓

𝑁𝑓𝑐𝑎𝑙 < 𝑁𝑓𝑔𝑖𝑣𝑒𝑛

∴ Design is unsafe

Take module Mn = 6

b = 10 *6 = 60 mm
𝑑 ∗𝑝 ∗ 𝑄∗ 𝑘
Fw = = 22533.4008 N
𝑐𝑜𝑠2 25

dp = 714.9888 mm

dg = 2144.9664 mm

𝑒 = 𝑒𝑝 + 𝑒𝑔 = 22.14 + 26.82 = 49.23 𝜇𝑚

e = 49.23 * 10^(-3) mm

C = 11400 e = 561.22 mm

V = 1.49 * 6 = 8.94 m/s

1.3 ∗1.1 ∗ 2502.34 3578.3462
Ft max = = = 596.39 N
𝑀𝑛 𝑀𝑛

𝑘𝑎 ∗ 𝑘𝑚 ∗ 𝐹𝑡 1.3 ∗ 1.1∗ 2502.34

Feff = = = 12243.0926 N
𝑘𝑣 𝐾𝑣∗ 𝑀𝑛

𝐹𝑤
Nf Cal = 𝐹𝑒𝑓𝑓 = 1.8404

Nf cal > Nf Given

Therefore, Design is safe

 Bevel Pair Design
Step 1. Beam Strength
𝑆𝑢𝑡𝑝 650
𝜎𝑏𝑝 = = = 216.67 𝑀𝑝𝑎
3 3

𝑆𝑢𝑡𝑔 700
𝜎𝑏𝑔 = = = 233.33 𝑀𝑝𝑎
3 3
𝑍𝑝 18
𝛾𝑝 = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 ( ) = 19.0934 𝑑𝑒𝑔𝑟𝑒𝑒
𝑍𝑔 52

𝑍𝑔 52
𝛾𝑔 = 𝑡𝑎𝑛−1 ( ) = 𝑡𝑎𝑛−1 ( ) = 70.9065 𝑑𝑒𝑔𝑟𝑒𝑒
𝑍𝑝 18
𝑍𝑝 18
𝑍′𝑝 = = = 19.0478
𝑐𝑜𝑠(𝛾𝑝 ) 𝑐𝑜𝑠(19.0934)

𝑍𝑔 52
𝑍′𝑔 = = = 158.9675
𝑐𝑜𝑠(𝛾𝑔 ) 𝑐𝑜𝑠(70.9065)

2.87
𝑌′𝑝 = 0.484 − = 0.3333
𝑍′𝑝
2.87
𝑌′𝑔 = 0.484 − = 0.4659
𝑍′𝑔

𝜎𝑏𝑝 ∗ 𝑌′𝑝 = 216.67 ∗ 0.3333 = 72.2161

𝜎𝑏𝑔 ∗ 𝑌′𝑔 = 233.33 ∗ 0.4659 = 108.7084

∴ 𝜎𝑏𝑝 ∗ 𝑌′𝑝 < 𝜎𝑏𝑔 ∗ 𝑌′𝑔

Pinion is weaker in bending.

𝑑𝑝 𝑑𝑔
𝑀𝑜𝑑𝑢𝑙𝑒 𝑚 = =
𝑍𝑝 𝑍𝑔

𝑑𝑝 = 𝑚 ∗ 𝑍𝑝 = 18𝑚

𝑑𝑔 = 𝑚 ∗ 𝑍𝑔 = 52𝑚

𝑑𝑝 𝑑𝑔 2 18𝑚 2 52𝑚 2 2
𝐴𝑜 = √( 2 ) + ( 2 ) = √( 2 ) + ( 2 )

𝐴𝑜 = 27.5136 𝑚
𝐴𝑜
𝑏 = 𝑚 𝑜𝑟 10𝑚 (whichever is minimum).
3
𝑏 = 9.1712𝑚
𝑏
𝐹𝑏 = 𝑚 ∗ 𝑏 ∗ 𝜎𝑏𝑝 ∗ 𝑌′𝑝 ∗ [1 − ]
𝐴𝑜
9.1712𝑚
𝐹𝑏 = 𝑚 ∗ 9.1712𝑚 ∗ 216.67 ∗ 0.3333 ∗ [1 − ]
27.5136𝑚
𝐹𝑏 = 441.5386 𝑚2 𝑁

Step 2. Wear Strength

2𝑍′𝑔
𝑄′ =
𝑍′𝑔 + 𝑍′𝑝

2(158.9675)
𝑄′ =
158.9675 + 19.0478
𝑄′ = 1.7859

𝐵𝐻𝑁 2 330 2
𝐾 = 0.16 ( 100 ) = 0.16 (100)

𝐾 = 1.7424

0.75 ∗ 𝑄′ ∗ 𝑘 ∗ 𝑏 ∗ 𝑑𝑝
𝐹𝑤 =
𝑐𝑜𝑠(𝛾𝑝 )

0.75 ∗ 18𝑚 ∗ 1.7859 ∗ 1.7424 ∗ 9.1712𝑚

𝐹𝑤 =
𝑐𝑜𝑠(19.0934)

𝐹𝑤 = 407.72106 𝑚2

Step 3. Beam Vs Wear Strength

𝐹𝑏 > 𝐹𝑤

⸫ Gear pair is weaker in pitting

Step 4. Preliminary Estimation

𝛱 ∗ 𝑑𝑝 ∗ 𝑛𝑝 𝛱 ∗ 18𝑚 ∗ 1440
𝑉 = =
60 ∗ 1000 60000

𝑉 = 1.3571𝑚
 𝑃𝑜𝑤𝑒𝑟 (𝑃) 3.725 ∗ 103 2744.6859
𝐹𝑡 = = =
𝑉 1.3571𝑚 𝑚

2744.6859
𝐹𝑡𝑚𝑎𝑥 = 𝐾𝑎 ∗ 𝐾𝑚 ∗ 𝐹𝑡 = 1.1 ∗ 1 ∗ 𝑚

3019.1544
𝐹𝑡𝑚𝑎𝑥 =
𝑚
6 6
𝐾𝑣 = =
6+𝑉 6 + 1.3571𝑚

𝐹𝑡𝑚𝑎𝑥 3019.1544 ∗ (6 + 1.3571𝑚)

𝐹𝑒𝑓𝑓 = =
𝐾𝑣 𝑚 ∗ 6

𝐹𝑤 = 𝐹𝑂𝑆 ∗ 𝐹𝑒𝑓𝑓

3019.1544 ∗ (6 + 1.3571𝑚)
407.72106 𝑚2 = 1.5 ∗
𝑚 ∗ 6

2446.3263 𝑚3 = 27172.3896 + 6145.9416𝑚

𝑚 = 2.603 ~ 3

Step 5. Precise Estimation

𝑏 = 9.1712 ∗ 3 = 27.5136 𝑚𝑚
3019.1544
𝐹𝑡𝑚𝑎𝑥 = = 1006.3848 𝑁
3

𝐹𝑤 = 407.72106 ∗ 32 = 3669.4895 𝑁

𝑑𝑝 = 𝑚 ∗ 𝑍𝑝 = 18 ∗ 3 = 54 𝑚𝑚

𝑑𝑔 = 𝑚 ∗ 𝑍𝑔 = 52 ∗ 3 = 156 𝑚𝑚

𝑉 = 1.3571 ∗ 3 = 4.0713 𝑚/𝑠

𝑑𝑝 𝑏
𝛾𝑚𝑝 = − 2 𝑠𝑖𝑛 (𝛾𝑝 ) = 27 − 13.7568 ∗ 0.3271 = 22.5 𝑚𝑚
2

𝑑𝑔 𝑏
𝛾𝑚𝑔 = − 𝑠𝑖𝑛 (𝛾𝑔 ) = 78 − 13.7568 ∗ 0.9449 = 65 𝑚𝑚
2 2
𝑒 = 11 + 0.9∅

𝑒𝑝 = 11 + 0.9(𝑚 + 0.25√2𝛾𝑚𝑝 ) = 15.2093 𝜇𝑚

𝑒𝑔 = 11 + 0.9(𝑚 + 0.25√2𝛾𝑚𝑔 ) = 16.2653 𝜇𝑚

𝑒 = 𝑒𝑝 + 𝑒𝑔 = 15.2093 + 16.2653 = 31.4746 𝜇𝑚

𝑐 = 11400𝑒 = 11400 ∗ 31.4746 = 358.8115 𝑚𝑚
21𝑉( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 )
𝐹𝑑 =
21𝑉 + √( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 )
21 ∗ 4.0713(27.5136 ∗ 358.8115 + 1006.3848)
=
21 ∗ 4.0713 + √(27.5136 ∗ 358.8115 + 1006.3848)

𝐹𝑑 = 4900.4235 𝑁

𝐹𝑒𝑓𝑓 = 𝐹𝑑 + 𝐹𝑡𝑚𝑎𝑥 = 5906.8083 𝑁

𝐹𝑤
𝑁𝑓𝑐𝑎𝑙 = = 0.6212
𝐹𝑒𝑓𝑓

𝑁𝑓𝑐𝑎𝑙 < 𝑁𝑓𝑔𝑖𝑣𝑒𝑛

∴ Design Is not Safe

Take module m = 6 mm.

𝑏 = 9.1712 ∗ 6 = 55.0272 𝑚𝑚
3019.1544
𝐹𝑡𝑚𝑎𝑥 = = 503.1924 𝑁
6

𝐹𝑤 = 407.72106 ∗ 62 = 14677.9581 𝑁

𝑑𝑝 = 𝑚 ∗ 𝑍𝑝 = 18 ∗ 6 = 108 𝑚𝑚

𝑑𝑔 = 𝑚 ∗ 𝑍𝑔 = 52 ∗ 6 = 312 𝑚𝑚

𝑉 = 1.3571 ∗ 6 = 8.1426 𝑚/𝑠

𝑑𝑝 𝑏
𝛾𝑚𝑝 = − 2 𝑠𝑖𝑛 (𝛾𝑝 ) = 54 − 27.5136 ∗ 0.3271 = 45 𝑚𝑚
2

𝑑𝑔 𝑏
𝛾𝑚𝑔 = − 𝑠𝑖𝑛 (𝛾𝑔 ) = 78 − 27.5136 ∗ 0.9449 = 130 𝑚𝑚
2 2
𝑒 = 11 + 0.9∅

𝑒𝑝 = 11 + 0.9(𝑚 + 0.25√2𝛾𝑚𝑝 ) = 18.5345 𝜇𝑚

𝑒𝑔 = 11 + 0.9(𝑚 + 0.25√2𝛾𝑚𝑔 ) = 20.0281 𝜇𝑚

𝑒 = 𝑒𝑝 + 𝑒𝑔 = 18.5345 + 20.0281 = 38.5625 𝜇𝑚

𝑐 = 11400𝑒 = 11400 ∗ 38.5625 = 439.6126 𝑚𝑚

21𝑉( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 ) 21 ∗ 8.1426(55.0272 ∗ 439.6126 + 503.1924)
𝐹𝑑 = =
21𝑉 + √( 𝑏 ∗ 𝑐 + 𝐹𝑡𝑚𝑎𝑥 ) 21 ∗ 8.1426 + √(55.0272 ∗ 439.6126 + 503.1924)
𝐹𝑑 = 12868.1311 𝑁

𝐹𝑒𝑓𝑓 = 𝐹𝑑 + 𝐹𝑡𝑚𝑎𝑥 = 13371.3235 𝑁

𝐹𝑤
𝑁𝑓𝑐𝑎𝑙 = = 1.5977
𝐹𝑒𝑓𝑓

𝑁𝑓𝑐𝑎𝑙 > 𝑁𝑓𝑔𝑖𝑣𝑒𝑛

∴ Design Is Safe
 Shaft design

Input shaft design -

Material for shaft : C40

➢ Sut = 600 Mpa
➢ Syt = 380 MPa

dp = 127.701 mm
Np = 1440 rpm

sut = 600 MPa

P = 5 HP = 3728.5 W

𝜙𝑛= 20 degrees and 𝜓 = 20 degrees

b = 60 mm
𝜌= 6330 kg/m3

𝛱 ∗ 𝑑𝑝 ∗𝑁𝑝 𝛱 ∗ 127.70 ∗ 1440

v = = = 9.6284 m/s
60000 60000

𝑃
Et = 𝑣
= (3728 * 5) / 9.6284 = 387.2398 N

387 ∗127.701
T = ft * 𝛾p = = 24725.45 N.mm
2

Fa = ft * (tan 𝜓) = 140.9437 N

𝑡𝑎𝑛 𝜙𝑛 𝑡𝑎𝑛 20
Fr = ft * = 387.2398 = 140. 9437 N
𝑐𝑜𝑠𝜓 𝑐𝑜𝑠 20

𝛱 𝛱
Volume = D^2 * b = * [127.701*10^(-3)]^ 2 * 0.06
4 4

Volume = 7.6847 * 10 ^ - 4 m^3

Length of input shaft = Length of intermediate shaft =L

 𝑏
L= 2 + 𝛿 + 𝐿′ + face width of bevel pinion + Diameter of bevel gear + (distance between
𝑏
bevel gear and helical gear ) + face width of helical gear +𝐿′ + 𝛿 + 2

L = 60/2 + 10 + 12.5 +50+274.5+ 10 +60+12.5 +10+60/2

L = 500 mm

Vertical Force Analysis

∑𝐹𝑦 =0
𝑅𝐴𝑉 +𝑅𝐵𝑉 +339.5243=0
𝑅𝐴𝑉 +𝑅𝐵𝑉 =-339.5243

∑𝑀𝐴 =0
417.5*339.5243+𝑅𝐵𝑉 *500=0
𝑅𝐵𝑉 = -283.502 N
𝑅𝐴𝑉 = -56.0263 N
𝐵𝑀𝐶 = -23389 N.mm
Horizontal Force Analysis

∑𝐹𝑦 =0
𝑅𝐴𝐻 +𝐹𝑟 +𝑅𝐵𝐻 =0
𝑅𝐴𝐻 +𝑅𝐵𝐻 = −𝐹𝑟 = -149.989
∑𝑀𝐴 =0
𝐹𝑟 *417.5+𝑅𝐵𝐻 *500-8999.3257 =0
𝑅𝐵𝐻 = -107.242 N
𝑅𝐴𝐻 = -42.747 N

𝐵𝑀𝐶 = -17847 N.mm

Resultant Bending Moment at point C,

𝐵𝑀𝐶 =M =√(𝐵𝑀𝐶 )2 𝐻 + (𝐵𝑀𝐶 )2 𝑉

M = 2942.41349 N.mm

𝑇𝑒 = √(𝐾𝑚 ∗ 𝑀)2 + (𝐾𝑇 ∗ 𝑇)2

𝐾𝑚 = 1.5, 𝐾𝑇 = 2
𝑇𝑒 = √(1.5 ∗ 29420.4134)2 + (2 ∗ 24725.45)2

𝑇𝑒 = 66278.75 N.mm
Ʈ𝑝𝑒𝑟 = 0.75 ( 0.3 *𝑆𝑦𝑡 𝑜𝑟 0.18 * 𝑆𝑢𝑡 )

(Considering Keyways Effect by ASME Code

Ʈ𝑝𝑒𝑟 = 85.5 Mpa ---- 𝑆𝑦𝑡 = 380 Mpa
𝜋
𝑇𝑒 = * 𝑑3 *Ʈ𝑝𝑒𝑟
16
1/3
66278.75
d= ( 𝜋 ) = 15.804 = 16 mm
∗85.5
16

d= 25 mm

Intermediate Shaft

𝜋∗𝑑𝑔∗𝑛𝑔
v= = 9.6284 m/s
60000

Forces On Helical gear

𝑃
𝐹𝑡 = 𝑉 = 387.2398 N
𝑡𝑎𝑛 Ø𝑛
𝐹𝑟 = 𝐹𝑡 * = 149.989 N
𝑐𝑜𝑠𝜓

𝐹𝑎 = 𝐹𝑡 (𝑡𝑎𝑛𝜓)
𝐹𝑎 =140.9437 N
𝜋
W = ϱvg =7700 * 4 * 𝐷2 𝑔 ∗ 𝑏 ∗9.81 = 522.4349 N
Forces On Bevel Gear (Pinion on intermediate shaft)

6000∗𝑃 6000∗3728.5
T= = = 74176.15 N.mm
2𝜋𝑁 2𝜋∗480
𝑃
𝐹𝑡 = 𝑉 = 1780.25 N

𝐹𝑟 = 𝐹𝑡 * 𝑡𝑎𝑛Ø* cos𝑟𝑝 = 1780.25*tan20* cos(19.9831)

𝐹𝑟 = 608.94 N
𝐹𝑎 = 𝐹𝑡 * 𝑡𝑎𝑛Ø* sin𝑟𝑔 = 1780.25*tan20* sin(70.016)

𝐹𝑎 =221.435 N
𝜋
W = ϱvg =7700* 4 * (100 ∗ 10−3 )2*(480.7695)* 10−3*9.8

W = 23.7854 N

Forces On Helical gear

𝐹𝑡 = 387.2398 N
𝐹𝑎 =140.9437 N
𝐹𝑟 = 149.989 N
W = 522.4349 N

Forces On Bevel Gear

𝐹𝑡 = 1780.25 N
𝐹𝑎 = 221.435 N
𝐹𝑟 = 608.94 N
W = 23.7854 N
Horizontal Force Analysis

∑𝐹𝑦 =0

𝑅𝐴𝐻 +608.94 − 149.989 + 𝑅𝐵𝐻 =0

𝑅𝐴𝐻 +𝑅𝐵𝐻 = -458.951

∑𝑀𝐴 =0
608.94 ∗ 77.5 + 11071.5 − 26997.977−149.989 ∗ 417.5 + 𝑅𝐵𝐻 *500 =0
𝑅𝐵𝐻 = -521.66 N
𝑅𝐴𝐻 = 62.708 N
BM Diagram 𝐵𝑀𝐶 = -51500 N.mm
Vertical Force Analysis

∑𝐹𝑦 =0
𝑅𝐴𝑉 + 1756.465 − 909.6747+𝑅𝐵𝑉 =0
𝑅𝐴𝑉 +𝑅𝐵𝑉 = -846.7903 N
∑𝑀𝐴 =0
1756.465*77.5-909.6747*417.5+𝑅𝐵𝑉 *500=0
𝑅𝐵𝑉 = + 487.31 N
𝑅𝐴𝑉 = -1334.1 N

Bending Moment Diagram 𝐵𝑀𝐶 = -103390 N.mm.

𝐵𝑀𝐶 =M =√(𝐵𝑀𝐶 )2 𝐻 + (𝐵𝑀𝐶 )2 𝑉

M =√(−103390)2 𝐻 + (−51500)2 𝑉

M = 112308.85 N.mm
𝐾𝑚 = 1.5, 𝐾𝑇 = 2

𝑇𝑒 = √(𝐾𝑚 ∗ 𝑀)2 + (𝐾𝑇 ∗ 𝑇)2

𝑇𝑒 = √(1.5 ∗ 112308.85)2 + (2 ∗ 74176.15)2

𝑇𝑒 = 224173.339 N.mm
Ʈ𝑝𝑒𝑟 = 85.5 Mpa
1/3
𝑇𝑒
d= ( 𝜋 ) = 23.735 = 25 mm
∗Ʈ𝑝𝑒𝑟
16

d= 35 mm

Output Shaft
Length of Shaft = Face width of bevel Gear + distance clearance +3*Assumed Diameter of
Shaft (for reference)
L= 50+10+75
L=135 mm

Forces On Bevel Gear

6000∗𝑃 6000∗3728.5
T= = = 203.455*103 N.mm
2𝜋𝑁 2𝜋∗175
𝑃
𝐹𝑡 = = 1781.8236 N
𝑉

𝐹𝑟 = 𝐹𝑡 * 𝑡𝑎𝑛Ø* cos𝑟𝑝 = 609.481 N

𝐹𝑎 = 𝐹𝑡 * 𝑡𝑎𝑛Ø* sin𝑟𝑔 = 221.640 N

W = ϱvg = 217.536 N
Vertical Force Analysis

∑𝐹𝑦 =0
𝑅𝐴𝑉 + 𝑅𝐵𝑉 =1999.341

∑𝑀𝐴 =0
𝑅𝐵𝑉 *75+1999.341*135=0
𝑅𝐵𝑉 = + 3598.8138 N
𝑅𝐴𝑉 = -1599.5

Bending Moment

A c B

-119960 N.mm

BMc = -119960 N.mm

Horizontal Force Analysis
Fr =609.48 N

A B C 30386.84N

60mm

RAH RBH

135 mm

𝛴𝐹𝑦 = 0
RAH + RBH = 609.481
𝛴𝑀𝐴 = 0
RBH × 75 + 30386.844 – 609.481 × 135 = 0
RBH = +691.901 N
RAH = -82.427 N

Bending Moment

30386.83

A C B

-6182

'
Resultant Bending Moment at C ,

M =√(−119960)2 + (−6182)2
M= 120119.1855 N.mm
Km = 1.5 , Kt = 2

∴ 𝑇𝑒 = √(𝐾𝑚 × 𝑀)2 + (𝐾𝑡 × 𝑇)2

∴ 𝑇𝑒 = √(1.5 × 120119.1855)2 + (2 × 203.4545 × 103 )2

∴ 𝑇𝑒 = 445016.0968 𝑁. 𝑚𝑚
𝜋
𝑇𝑒 = × 𝑑 3 × 𝜏 𝑝𝑒𝑟
16
1
445016.0968 3
𝑑=[ 𝜋 ] = 29.1167 ~ 32 𝑚𝑚
×85.5
16

𝑑 = 45 𝑚𝑚

Design of Gearbox Casing

Length of Casing = length of intermediate shaft +10 mm clearance from each side.
L= 500+20= 520mm
L= 520mm
Height of gearbox Casing = Diameter of Helical Gear + Clearance
= 400mm
H= 400mm
B= 520mm
2𝐿+𝐵+𝐻 2 ×520+520+400
N= =
4 4

N=0.49 m
From Design Data Book
t= 8mm
 Design of Keys

Type : Rectangular Sunk Keys

Material : C35
D= 25 mm
2𝜋𝑁𝑇
𝑃=
60
2𝜋𝑁𝑇
3728.5 =
60
∴ 𝑇 = 24725.38355 𝑁. 𝑚𝑚

Key Dimensions
𝐷 25
𝑏= = = 6.25 𝑚𝑚
4 4
𝐷 25
ℎ= = = 4.1667 𝑚𝑚
6 6

Consider Shear,
𝑑
𝑇 = 𝑤×𝑙× × 𝜏 𝑝𝑒𝑟
2
0.5 × 𝑠𝑢𝑖𝑡 0.5 × 280
𝜏 𝑝𝑒𝑟 = = = 70 𝑀𝑝𝑎
𝐹𝑂𝑆 2
25
∴ 24725.38355 = 𝑙 × 6.25 × × 70
2
∴ 𝑙 = 4.52 𝑚𝑚

Considering Crushing
𝑙ℎ𝑑
𝑇= × 𝜏 𝑝𝑒𝑟
4
24725.38355 × 4
𝑙= = 13.563 𝑚𝑚
4.1667 × 25 × 70
By design Consideration , length of Keys Should Cover 60% of Face Width of Gear,
∴ 𝑙 = 0.6 × 60 = 36𝑚𝑚
Considering largest length ,
L= 36 mm

Design Check :-
ℎ 𝑑
𝑇= × 𝑙 × × 𝜎𝑐 𝑝𝑒𝑟
2 2
𝜎𝑐 𝑝𝑒𝑟 = 26.3735 < 𝜎𝑐 𝑔𝑖𝑣𝑒𝑛
∴ 𝐷𝑒𝑠𝑖𝑔𝑛 𝑖𝑠 𝑆𝑎𝑓𝑒.

Intermediate shaft
d= 35mm.
T=74176.15 N.mm
𝑑 35
𝑏= = = 8.75𝑚𝑚
4 4
𝑑 35
ℎ= = = 5.833𝑚𝑚
6 6
Consider shear,
𝑙𝑤𝑑
𝑇= × 𝜏 𝑝𝑒𝑟
2
74176.15 × 2
= 𝑙 = 6.92𝑚𝑚
8.75 × 35 × 70

Consider Crushing,
𝑙ℎ𝑑
𝑇= × 𝜏 𝑝𝑒𝑟 = 74176.15
4
∴ 𝑙 = 20.76𝑚𝑚
Length for 60% of face width
𝑙 = 0.6 × 60 = 36𝑚𝑚 -------Helical Gear
𝑙 = 0.6 × 50 = 30𝑚𝑚--------Bevel Gear
Design Check
𝑇×4
𝜎 𝑐 𝑖𝑛𝑑𝑢𝑐𝑒𝑑 = = 40.368 < 𝜎𝑐 𝑔𝑖𝑣𝑒𝑛
36 × 6.833 × 35
∴ 𝐷𝑒𝑠𝑖𝑔𝑛 𝑖𝑠 𝑠𝑎𝑓𝑒.

Output shaft
𝑑 = 45𝑚𝑚
𝑇 = 203.455 × 103 𝑁. 𝑚𝑚
𝑑 45
𝑏= = = 11.25 𝑚𝑚
4 4
𝑑 45
ℎ= = = 7.5 𝑚𝑚
6 6

Consider Shear
𝑙𝑤𝑑
𝑇= × 𝜏 𝑝𝑒𝑟
2
203.455 × 103 × 2
𝑙= = 11.482𝑚𝑚
45 × 11.25 × 70

Consider Crushing
203.455 × 103 × 4
𝑙= = 34.447 𝑚𝑚
45 × 7.5 × 70
60% of face Width.
𝑙 = 0.6 × 60 = 30𝑚𝑚
Consider largest length l= 35mm

Design Check,
𝑇×4
𝜎𝑐 𝑖𝑛𝑑𝑢𝑐𝑒𝑑 = = 68.89 < 𝜎𝑐 𝑔𝑖𝑣𝑒𝑛
𝑙×𝑤×𝑑
∴ 𝐷𝑒𝑠𝑖𝑔𝑛 𝑖𝑠 𝑆𝑎𝑓𝑒 .
Key Dimension

𝐼𝑛𝑝𝑢𝑡 𝑆ℎ𝑎𝑓𝑡 𝐾𝑒𝑦 6.25 × 4.166 × 36

𝐼𝑛𝑡𝑒𝑟𝑚𝑒𝑑𝑖𝑎𝑡𝑒 𝑆ℎ𝑎𝑓𝑡 𝐾𝑒𝑦 8.75 × 5.833 × 36

8.75 × 5.833 × 30

𝑂𝑢𝑡𝑝𝑢𝑡 𝑆ℎ𝑎𝑓𝑡 𝐾𝑒𝑦 11.25 × 7.5 × 35

Bearing Design And Selection

1] FOR INPUT SHAFT-

D= 25 mm
Fa = 140.9434 N
Fr = 317.6313 N
Ka = 1.5

Bearing selected “ Deep Groove Ball Bearing “ (Extra light series) - 6005

Static load capacity , 𝐶0 = 5600 N

Dynamic load capacity, C = 112000 N
Now,
𝐹𝑎
= 0.025
𝑐0

𝐹𝑎
= 0.44
𝐹𝑟
𝐹𝑎
Since, e = 0.22 so, > e
𝐹𝑟

We Know ,
Pe = [ XVFr + YFa ] * Ka
 By putting values X= 0.56 , Y =2
Pe = [0.56 * 1 * 317.6313 + 2 * 140.9437 ] *1.5

Pe = 689.64 N

finding 𝐿10 life by 𝐿ℎ10 = 20000 𝐻𝑟𝑠

𝐿ℎ10 ∗ 60∗ 1440

𝐿10 = = 1728 m rev
10 6

𝐶𝑟
𝐿10 = (𝑃𝑒)𝑎 Here, a=3 [Because it is Ball bearing]

By Calculating We get,
Cr = 8275.92 N

Cr = 8275.92 N

clearly , [ Cr < C ]
Therefore , Bearing chosen is correct and suitable.

2] FOR INTERMEDIATE SHAFT -

D = 35 mm
Fr = 1767.67 N
Fa = 221.431 N
Ball bearing Selected - 6007 By DDB page no. 4.12 - 4.14

hence ,
Static load capacity , 𝐶0 = 8500 N
Dynamic load capacity, C = 15900 N
Now,
𝐹𝑎
= 0.026
𝑐0
 𝐹𝑎
= 0.125
𝐹𝑟
𝐹𝑎
Since, value of is slightly greater than 0.025 , it will be predicted that value of e will be lie
𝑐0
between 0.22 to 0.24
𝐹𝑎
Now ,𝐹𝑟 will always less than (e = 0.22)

We Know ,
Pe = [ XVFr + YFa ] * Ka
By putting values X= 1 , Y =0
Pe = 2651.505 N

Pe = 2651.505 N

𝐿10 = 576 m rev

𝐶𝑟
𝐿10 = (𝑃𝑒)𝑎 Here, a=3 [Because it is Ball bearing]

By Calculating We get,
Cr = 22061.41 N

Cr = 22061.41 N

So , [ Cr > C ]
But 6207 bearing has C value of 28000 N
So, [ Cr < C ]
Hence form DDB page no 4.12 - 4.14 bearing catalogue Selected bearing is correct
Then the selected bearing is 6207.
3] FOR OUTPUT SHAFT -

D = 45 mm
Fr = 691.908 N
Fa = 2812.985 N
Ball bearing Selected - “Deep groove ball bearing ” series - 6007
……(By DDB page no. 4.12 - 4.14)
\

hence ,
Static load capacity , 𝐶0 = 12200 N
Dynamic load capacity, C = 21200 N
Now,
𝐹𝑎
= 0.0567
𝑐0

𝐹𝑎
= 0.24
𝐹𝑟
𝐹𝑎
Since, value of is in the range 0.04 and 0.07 , so e will be lie between 0.22 to 0.24
𝑐0

𝐹𝑎
Now ,𝐹𝑟 =0.24 < e always

We Know ,
Pe = [ XVFr + YFa ] * Ka
By putting values X= 1 , Y =0
Pe = 4219.4775 N

Pe = 4219.4775 N

𝐿ℎ10 = 20000 𝐻𝑟𝑠

𝐿ℎ10 ∗ 60∗ 𝑁
𝐿10 = = 210 m rev
10 6

𝐶𝑟
𝐿10 = (𝑃𝑒)𝑎 Here, a=3 [Because it is Ball bearing]
 By Calculating We get,
Cr = 25080.2449 N

Cr = 25080.2449 N

here, [ Cr > C ]
But 6209 bearing has C value of 33200 N - BY DDB
So, [ Cr < C ]
Hence form DDB page no 4.12 - 4.14 bearing catalogue Selected bearing is correct
Then the selected bearing is 6209.
 Standard Parts Selection
[1] Lubricating Oil
a) Kinematic Viscosity – 16.5 – 18.5
b) SAE Grade – 90
c) Viscosity Index – 85
d) Flash Point(°C)(Min) – 180
e) Pour Point (°C)(Max) - -9

[2] Eyebolt (Catalogue)

Total Number of eyebolts = 3

Weight of Assembly = 170 kg = 0.17 tonnes
∴ 𝑓𝑜𝑟 𝐶𝑜𝑛𝑠𝑖𝑑𝑒𝑟𝑖𝑛𝑔 𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑠𝑎𝑓𝑒𝑡𝑦,
For 0.23 tonnes , eyebolts are M20.

[3] Gasket
Gasket is 5mm thick covering total periphery of gearbox.

[4] Air Breather

Air Breather is according to M10, threaded length of 10mm was Selected

[5] Bolts/ fasteners

M20 nut and bolts hexagonal headed selected.

[6] Drain Plug

Metric 10 Drain plug was selected.
Final Dimension
1]Helical pair – Module = 6
Helical pinion diameter – 127.701 mm
Helical gear diameter- 383.103mm
No of teeth on pinion- 20
No of teeth on gear- 60

2] Bevel Pair – Module =5

Bevel Pair pinion diameter 100 mm
Bevel gear diameter 274.2 mm
No of teeth on pinion 20
No of teeth on gear 55

3] Bearings & Shaft

Shaft 25 mm 35 mm 45 mm
Bearing 6005 6207 6209
Keys 6.25 ×4.16×36 8.75 ×5.83×36 11.25 × 7.5×36

4] Casing Design = [520×520×400] mm

and t= 8 mm.

-----------------------