ARBAMINCH UNIVERSITY INSTITUTE OF TECHNOLOGY

FACULITY OF MECHANICAL ENGINEERING

Design of Spur Gearbox for Blenders

Prepared By: Biniyam Abera RAMIT/301/10

List of figures
List of tables
 Nomenclature of symbols

A-Centre distance 𝜎𝑏- bending stress

b- Face width 𝜎𝑐- compressive stress
C- Dynamic load capacity 𝜏- shear stress
Cv- Velocity factor P- power
Cs- Service factor Zp- number of teeth on planet
Zs- number of teeth on sun ZR- number of teeth on ring
Db= bore diameter Y- lewis form factor
Di= internal diameter
d0= outer diameter
dp-pitch diameter of planet gear.
ds- pitch diameter of sun gear.
dr- pitch diameter of ring gear.
l- length
L10- life in hours
M/m- module
Pd- dynamic load
Peff- effective load
Pt- tangential load
Pr- radial load
R-gear ratio
rp- radius of planet gear
rs- radius of sun gear
rR- radius of ring gear
Sb- beam strength
Sw- wear strength
Syt- tensile yield stress
t= thickness
TA- input torque
TB- output torque
V- Velocity
W- Weight
 Abstract

A goad gearbox could be a gearbox that employments goad gears for transmitting control from
the Control source to the output shaft. The gearbox is planned within the application zone of
blenders. The lack of easiness and utilization of time whereas blending an fixing could be a
genuine issue of concern to numerous nourishment and chemical businesses. Since the blending
prepare isn't palatable, it is basic to plan a machine to unravel or minimize the expressed issue.
This ponder is planning to plan a goad gearbox that can be utilized in blenders. This think about
is conducted by recognizing issue, collecting the vital information and analyzing impacts on
nourishment businesses. Investigation, plan and recreation of the machine was carried out by
numerical calculation, strong works modeling and recreation. The consider brought about in a
machine that minimizes the speed and maximize the torque with ideal taken a toll.
KEY WORDS: Strong works, Blenders, Investigation, Adapt, Shaft
 CHAPTER ONE
INTRODUCTION

A blender is an industrial and kitchen /laboratory appliance used to mix, crush, pure or
emulsify food and other substances. A stationary blender consists of a blender container with a
rotating metal blade at the bottom, powered by an electric motor that is in the base. Some
powerful models can also crush ice and other frozen foods.

Different blenders have different functions and features but product testing indicates that many
blenders, even the less expensive ones, are useful for meeting many consumer needs. The mixing
of particulate ingredients involves the movement of the ingredients throughout each other, in an
effort to produce a uniform distribution of each component throughout the mix.

To emulsify this ingredient there should be a power transmission that connects the source of
power to the blades.

The gearbox of a blender is used for this purpose.

Gearbox is a device that used for transmitting power from the Power source to the output shaft or
in other words a Gearbox is a mechanical device utilized to increase the output torque or change
the speed of a motor. The motor's shaft is attached to one end of the gearbox and through the
internal configuration of gears of a gearbox, provides a given output torque and speed
determined by the gear ratio. A gearbox has a set of gears that are enclosed in a casing. The gears
are mounted on shafts which rotate freely about their axis. The gears are fixed on the shafts by
Fits or by a key. These shafts are made to rotate freely on a support called casing. Bearings are
tightly fit between the shafts and the casing. Many of today’s machines have various sets of
gears which give different speeds and torque on different Gears. Each Gearbox has its own set of
Gear ratios that can be selected by the user or just one set of universal Gear. Major components
include gears, Casing, Shafts, and Bearing

Types of Gearboxes

There are many types of gearboxes manufactured throughout the world. One of the main
differences between individual gearboxes is their performance characteristics. Choosing from the
various gearbox types is application dependent. Gearboxes are available in many sizes, ratios,
efficiencies and backlash characteristics. All of these design factors will affect the performance
and cost of the gearbox. There are several types of gearboxes which are listed below:

 Spur Gearbox
 Bevel Gearbox
 Helical Gearbox
 Worm Gearbox
 Planetary Gearbox

Spur Gearbox Spur gears are made with straight teeth mounted on a parallel shaft. The noise
level of spur gears is relatively high due to colliding teeth of the gears which make spur gear
teeth prone to wear. Spur gears come in a range of sizes and gear ratios to meet applications
requiring a certain speed or torque output. Spur gears are mounted in series on parallel shafts to
achieve large gear reductions. The most common gears are spur gears and are used in series for
large gear reductions. The teeth on spur gears are straight and are mounted in parallel on
different shafts. Spur gears are used in washing machines, screwdrivers, windup alarm clocks,
and other devices. These are particularly loud, due to the gear tooth engaging and colliding. Each
impact makes loud noises, which is why spur gears are not used in machinery like cars. A normal
gear ratio range is 1:1 to 6:1.
Spur gears are one of the most popular types of precision cylindrical gears. These gears feature a
simple design of straight, parallel teeth positioned around the circumference of a cylinder body
with a central bore that fits over a shaft. In many variants, the gear is machined with a hub which
thickens the gear body around the bore without changing the gear face. The central bore can also
be broached as to allow the spur gear to fit onto a spline or keyed shaft. Spur gears are used in
mechanical applications to increase or decrease the speed of a device or multiply torque by
transmitting motion and power from one shaft to another through a series of mated gears.
spur gear terms

 Pitch Circle: The circle derived from a number of teeth and a specified diametral pitch.
The circle in which tooth spacing or profiles are established from which tooth proportions
are constructed.
 Diametral Pitch: Ratio of the number of teeth to the pitch diameter.
 Pitch Diameter: Is the diameter of the pitch circle. This is where a spur gears angular
velocity is measured. This is also a critical component for determining center distances
between mating spur gears.
 Center Distance: The distance between two gears, measured from the center shaft of one
gear to the center shaft of the mating gear. This can be found roughly by taking the radius
of each spur gears pitch circle and adding them together.
 Module: The ratio of the reference diameter of the gear divided by the number of teeth.
Module is the metric equivalent to diametral pitch.
 Addendum: The height by which a tooth projects beyond the pitch circle.
 Dedendum: The depth of a tooth space below the pitch circle. Generally greater than the
addendum of the mating gear to provide clearance.
 Outside Diameter: The diameter of the addendum circle, or the circle along the outermost
points of a spur gear’s teeth. This measurement is the largest diameter spur gears have.
 Root Diameter: The diameter at the base of the tooth space.
 Pressure Angle: The angle at a pitch point between the line of pressure which is normal to
the tooth surface, and the plane tangent to the pitch surface.
 Whole Depth: The total depth of tooth space, equal to the addendum plus the dedendum.
There are two types of spur gearboxes depending on their purpose

 Reduction gearbox: is a device by which an input speed can be lowered for a requirement
of slower output speed, with same or more output torque.
 Multiplication gearbox: is a device by which an input speed can be increased for a
requirement of faster output speed, with same or less output torque
Types of Spur Gear:

There are three important types of Spur Gear and those are:

 External Spur Gear

 Internal Spur Gear and

 Spur Rack and Pinion.

External Spur Gear:

These spur gears have external teeth on the outer surface of the cylinder. When the two gear
meshes both will Rotate in the opposite direction. The driver is usually smaller in size & Driven
is moved in the opposite direction to the Driver.

External Spur Gear

Internal Spur Gear:

In internal spur gear, teeth are cut on the internal/inner surface. This gear will be like a ring into
that pinion or smaller gear meshes inside it & the two shafts will Rotate in the same direction.

Internal Spur gear

 1.1 BACKGROUND

Recent advancements in mixer and blender designs have helped food firms achieve greater
success by meeting their demand for consistency and generating new products while cutting
manufacturing costs.

Nowadays, engineering design is an iterative process that must be addressed in all possible ways.
Create solutions in order to achieve the desired result. The proper gearbox design has a huge
impact. position in a variety of applications Traditional design methodologies are incapable of
achieving this.

The procedure is being automated. As a result, an attempt has been made to automate the
preliminary design of a gearbox. carried out in the paper A program that automates the
preliminary design of a spur gearbox. It was created helical and bevel gears.

The size, weight, transmission, and machine performance all benefit from precise spur gear drive
design. In many applications, lighter gears are also in high demand since they save material and
energy. As a result, the research proposes an improved strategy for resolving a two-stage spur.

The difficulty of gear optimization. It is made up of a mathematical model with a well-defined

goal function. A Two-stage spur gear is taken into account. The purpose of the project is to
acquire the smallest amount of spur gear drive possible.

The following design variables are taken into account: module, number of teeth, gear base width,
and shaft width. diameter and strength Aside from conventional mechanical limits based on
industry standards, requisites, as well as other more serious limitations on contact ratio, load
bearing capability, and power loss, are imposed on the gearbox.

The dynamic behavior of multi-stage gearboxes is becoming increasingly essential in times of

mixing. The manufacturing quality of the gears is one aspect that is influenced by the production
process, among other things.

The goal of this project is to analyze dynamic behavior with a dynamic focus.

interplay between two-stage gearboxes To do this, gears of various geometries and the
Mathematically, interactions between meshes are examined.
The specifications of the preliminary design For pinion and gear, the module, number of teeth,
and tooth width are all important. Gear ratios were chosen in relation to the objective by
optimizing pairs of stages. restrictions in terms of function and design

1.1. PROBLEM STATEMENT

Random blender machines can not mix high loads for example ice and high density fruits so we
have to design a special blender that have extra force and that can perform extra work.

Therefore, this study focuses on solving the stated problem by designing a simple and efficient
design of spur gearbox of a blender

1.3. OBJECTIVE

1.3.1. General objective

The main objective of this study is to design, model and analyze a spur gearbox that can be used

in Blenders.

1.3.2. Specific objective

The specific objectives of this study are:

 to design components of a spur gearbox that can be used in Blenders.

 to draw a 2D and 3D drawing of the components
 to select a material that is suitable for each components
 to show simulation and motion study of the machine using CAD software

1.5. SCOPE OF THE STUDY

This ponders bargains with the plan, examination and improvement of goad gearbox in blenders.
This consider focuses on goad gearbox of organize two that works up to 2500 rpm and 7hp input
speed and control respectively within the application range of blenders (mixing machine). The
gearbox features a plan life of 12000hrs with a working temperature of 1000 c and a adapt
proportion of 3.5. The plan and creating of the item employments numerical approach and
analysis. Note: This ponder is restricted as it were in planning and modeling of the item.
Adjusting a model and fabricating the components isn't included.

1.6. METHODOLOGY

Problem identification: In this organize the issue is distinguished and stated.

Literature Review

In this arrange already recorded works related to goad gearboxes and gears in industrial blenders
are considered surveyed. The most center of the audit will be in already designed goad
gearboxes, their component, operation standards, proficiency and limitations

Collection of data: In this stage all necessary data that will be used in the design process are
collected and compiled.
Detail design analysis: In this stage all necessary numerical parameters are determined and listed
using geometrical analysis, force analysis and stress analysis on different parts of the gear box.
The fit and tolerance of components, manufacturing process, assembly procedures and cost
analysis of the components is also performed

Conclusion and Recommendation: In this arrange conclusion on the plan handle is given and
recommendations on diverse operational perspectives of the gearbox are given.
 CHAPTER TWO

LITERATURE REVIEW

A blender as stated earlier is an industrial and kitchen or laboratory appliance used to mix, crush,
purée or emulsify food and other substances.

The food industry produces a wide variety of particulate mixtures which combine a wide variety
of ingredients such as sugars, flour, dairy products, salt, dried cereals, vegetables and fruits.

Mixing of these particulate ingredients involves the movement of the ingredients to accomplish
the mix. To emulsify this ingredient there should be power transmissions that connect the source
of power to the blades. The gearbox of a blender is used for this purpose.

Reduction gearbox: A reduction gearbox is a device by which an input speed can be lowered
for a requirement of slower output speed, with same or more output torque. Reduction gear
assembly consists of a set of rotating gears connected to an output shaft. The high speed
incoming motion from the wheel work is transmitted to the set of rotating gears, wherein the
motion or torque is changed. The number of gears used in the reduction gear assembly depends
on the output speed requirement of the application. The reduction gear assembly is usually
known as reduction gear box. Depending on the Output speed required, the reduction may have
single stage or two stage reTypes of Reduction Gearbox

There are mainly two types of reduction gears:

 Single reduction gear

 Double reduction gear

Single Reduction Gear: This arrangement consists of only one one pair of gears. The
reduction gear box consists of ports through which the propeller shaft and engine shaft enters the
assembly. A small gear known as a pinion is driven by the incoming engine shaft. The pinion
directly drives a large gear mounted on the propeller shaft. The speed is adjusted by making the
ratio of the speed reduction to the diameter of pinion and gear proportional. Generally, a single
gear assembly has a gear double the size of a pinion.

Double Reduction gear

Double reduction gears are generally used in applications involving very high speeds. In this
arrangement the pinion is connected to the input shaft using a flexible coupling. The pinion is
connected to an intermediate gear known as the first reduction gear. The first reduction gear is
then connected to a low speed pinion with the help of one more shaft. This pinion is connected to
the second reduction gear mounted directly on the propeller shaft. Such arrangement facilitates
the reduction of speed to a ratio as high as 20:1.
Kharles Ross & Loun Company (2013) This paper studies the design of spur gear mechanism in
a Blender gearbox. The mechanism which consists of 3 shaft with keyway cutting and four Spur
gear mechanism shifted from R-L moves in forward direction. Some parameters such as wear,
friction, rusting etc. can affect the reduction ratio of the 2-staged speed reduction spur gearbox of
the blender. In the design and fabrication of the spur gearbox we get to know about the
mechanism and concluded that spur gearbox is the suitable solution for the blender because of its
easiness to be manufactured and cost effectiveness. It is 2 stage reduction gearbox that is induced
with efficient output and comparatively lesser weight. The blender is used to mix or emulsify
ingredients. With the help of the forward drive from the gear output shaft, the blades liquidize
and mix the input. In conventional method of mixing the gearbox plays a vital role. The driving
motor runs the input shaft of the gear box at a speed of around 3200rpm, which in return rotates
the first staged gear arrangements by a gear ratio of GR=3. Since the gearbox is made up of spur
gears, there is some unnecessary noise, so to prevent this it is suggested to use a periodic
lubrication. The spur gearbox is designed to be a reduction gearbox for the purpose of mass
production at one time. This paper presented the properly mixing blender machine that use a spur
gearbox.

Suraj P. Mail (2016) proposed that now a days mixing has become most important part in Food
and bakery industries, large kitchens and Sugar factory. This paper describes about the
mechanical design and analysis of spur gearbox in a blender machine that is used to mix
ingredients. As we all knew that mixing is a very important processing in any chemical, paints
and food process industry. To attain the uniform mixing of the solution with the desired quality
and cost the newly designed gearbox is suggested. The gearbox designed is safe affordable of
performance efficient with respective speed and torque required to clear the dynamic event
satisfactorily.

Helmut Brod, (2011) this research paper aims to study the various types of Blender gearboxes,
discuss the advantages of the spur gear boxes over all the other type of gearboxes, and study the
various components of the spur gear box in detail. The mixing is certainly the most critical phase
of the blender and the quality of the mixed output depends heavily on the quality of the gearbox.
Due to the financial efficiency and other reasons, the spur gearboxes meet the requirements of
various production processes.

Osokam Shadrach ONYEGU et al. (2012) this paper presents the design and fabrication of a
spur gearboxes of an industrial blender. It is designed to work with a speed of 1500rpm and feed
was done in the MS Excel environment for proper machine design approach. The machine was
designed using SOLIDWORKS 2D/3D design software and proper material selection was done
before the assembling and fabrication of parts. Proper design analysis was carried out on the
machine to avoid failure on both the gears and the shaft. All this achieved by studying the gear
ratio and various resistance acting on the blender, calculation of gear, shaft, bearing etc. with
respect to force, speed, density, and other parameters. The design and its simulation is covered
by SOLIDWORKS.

John M. Hawkins [2005] simplified the design of a gearbox and made it more compact for usage
in low power vehicles like Mopeds and Forklifts. He even analyzed the current flaws in
reduction gearbox which were either reduced or nullified in his design. His design was so
compact that it is being used in Helicopters to increase the torque which has reduced the startup
time of the rotors.

Ralph E.Taggert [2008] made a detailed experimental study on ‘Forces that affect the operation
and efficiency of reduction Gearbox’ that contributes the complete information about a single
stage reduction gearbox that includes dimensions of the real time gyroplane parts, the parts used
in the Gearbox, assembly of individual components of the Gearbox, Gearbox mounting, VT
mounting and Differential mounting in Automobiles.
 Sellgren, U.; Akerblom, M. [2015] have done extensive studies on the gearbox to study the
origin of noise at high speeds. Noises in gearbox are a sign of inefficient operation and faster
wear of 9 components. It has been observed that the origin of noises is from improper meshing of
gears in the assembly. This mostly happens due to not giving 11 proper clearances between gear
train that cause either huge Backlash or interference hence leading to faster wear.
 CHAPTER THREE

PRELIMINARY DESIGN

Gearboxes are commonly utilized in movement control applications to alter the yield speed and
torque from an engine to a driven component. By employing a littler adapt with less teeth
(commonly alluded to as a pinion) to drive a larger adapt with a better number of teeth, the
torque delivered to the stack is expanded whereas the rotational speed to the stack is diminished.

With single spur gears, a combine of gears shapes a adapt organize. In case you interface a few
adapt sets one after another, this is often known as a multi-stage gearbox. For each adapt arrange,
the course of revolution between the drive shaft and the yield shaft is reversed.

A multi-stage gearbox simply combines two or more pairs, or stages, of gears, with the output of
one stage connected to the input of the next. The resulting gear ratio is the product of the gear
ratios of each stage. In general, two stage gearbox means in which the torque is stepped down or
up twice that is using two pairs of gears.

Spur gears are generally seen as best for applications that requires speed reduction and torque

Multiplication. So, reduction gearboxes are mechanical devices that alter the primary input speed

Received from a driving source into a different output speed by using a gear or a series of gears.

3.1. Formal need statement

This gearbox is expected to transfer a primary input rotational speed received from a driving
source of 2500rpm to an output shaft by a 7hp input power. The gearbox is a two-stage spur
gearbox and the output speed is reduced twice by the two stages with a gear reduction ratio of
3.5, which makes the output speed to be 3.5 times less, that is 714.3rpm. This results in a
multiplication of torque. So in general this gearbox is a reduction type gearbox that is used to
increase torque (3.5 times)while reducing the speed of a prime mover output shaft.

The gearbox is a 2-stage reduction spur gearbox in the application area of Blenders.

3.2. Source of power and mechanism

Blender is an industrial and kitchen appliance used to mix, crush, purée or emulsify food and
other substances. This blender is used in the food industry that produces a wide variety of
particulate mixtures which combine a wide variety of ingredients such as sugars, flour, dairy
products, salt, dried cereals, vegetables and fruits.
Different types of Industrial blenders
A blender comprises of a blender holder with a turning metal edge at the foot needs a control
source to operate. So to achieve this assignment, fueled electric engines are utilized for the most
part. This motors as their title proposes employments electric control as a source of their control.

The electric engine is an electrical machine that changes over electrical vitality into mechanical
energy. Most electric engines work through the interaction between the motor's attractive field
and electric current in a wire winding to create constrain within the shape of torque connected on
the motor's shaft. This electric engines can be fueled by coordinate current (DC) sources, such as
from batteries, or rectifiers, or by rotating current (AC) sources.
Different types of Electric motors

3.3. Technical object

 Shafts: a rotating element that is used to transmit power from the power source (motor) to
the power absorber (blades).
 Pinion: is the smaller of the two meshed gears.
 Housing: is a protective casing which surrounds the components of the gearbox.
 Bearing: is a rolling element that is used to support the shafts and allow rotation between
the shaft and the housing.
 Gears: A rotating circular machine part having cut teeth, which mesh with another
toothed part to transmit torque.

3.4. Specification and expected outcome

The gearbox is a 2-stage reduction spur gearbox in the application area of Blenders. The spur
gears

are used to transfer motion and torque between the machine (blender)components. This makes a

difference b/n the input value and the outcome (output value) that enters and leave the gearbox.

Given specifications

 Type of gearbox – Spur gearbox

 Gear ratio – 3.5
  Input power – 7hp
 Input speed – 2500rpm
 Working temperature – 100 0C
 Application area – Blenders
 Design life – 12000hr

Since the gearbox is a reduction type gearbox, the input torque is multiplied 3.5 times when it
reaches the output shaft, in reverse the input speed is lowered 3.5 times when it reaches the
output shaft.

So in general the expected outcome of this project is an efficient spur gearbox with an output
speed reduced with a rate of 3.5 and an output torque increased with the same rate.

3.5. Development of alternative solutions

The gearbox is expected to deliver the required torque and speed to the blenders blades. To

accomplish this target, the gearbox should work at its very best. This gearbox’s internal system

and mechanism can be designed based on different mechanisms for the sake of efficient work
with

cost reduction. Some of them are: -

3.5.1. Based on shaft alignment

It’s a process of aligning two or more shafts with each other to within a tolerated margin.

 Horizontal shaft alignment

 Vertical shaft alignment
 Eccentric shaft alignment

3.5.2. Based on the gear mesh

It’s a prepare of making gears to have contact to each other for the reason movement
transmission. The sorts of adapt that are planning to be utilized within the gearbox is goad gears,
since not only they can be manufactured effectively but moreover their fetched adequacy and
effectiveness is nice compared to other gears.

3.5.3. Based on bearing type

It’s a rolling element that is used to support the shafts and allow rotation between
the shaft and the housing. bearing There are many types of bearings available, but
the most common types are:

 Plain bearing, consisting of a shaft rotating in a hole. There are several

specific styles: bushing, journal bearing, sleeve bearing, rifle bearing,
composite bearing;
 Rolling-element bearing, in which rolling elements placed between the
turning and stationary races prevent sliding friction. There are two main
types:
- Ball bearing, in which the rolling elements are spherical balls
- Roller bearing, in which the rolling elements are Rollers

 Ball bearing
3.5.4. Based on Lubrication system

There are several methods for lubricating a gearbox, with the most common being grease
lubrication and oil splash.

Grease lubrication is suitable for low-speed operation, but it provides less cooling than oil, and
is not recommended for continuous-duty or heavily loaded applications, even at low speeds.

Oil splash lubrication is often used for helical, spur, and bevel gearboxes. This method is also
referred to as an oil bath, because it uses a reservoir is filled (or partially filled) with oil. As the
gears rotate, they dip into this oil bath and splash the oil onto the other gears and bearings. But if
the gear teeth are fully submerged, a condition known as “churning” occurs.

3.5.5. Housing Type

The gear housing is a mechanical housing that surrounds the mechanical components of a gear
box. It provides mechanical support for the moving components, a mechanical protection from
the outside world for those internal components, and a fluid-tight container to hold the lubricant
that bathes those components.

 A Split housing is like a walnut shell, the housing is divided in two parts, and lower part
that tie down the Gear Box to the structure, support all the components during the
assembly stage and hold the lubrication oil; and the upper part that complete the
enclosure and provide mechanical integrity to the Housing.
 The upper and lower parts of the housing have a mating surface that seals perfectly the
housing to avoid oil leaks and fatigue of the housing.
 A bathtub housing is made on a single piece and have a top opening for servicing the gear
box and side opening to accommodate the bearing housing associated to the gear shafts.
Have in general a better leak free performance but is more difficult to assemble and
repair.

After all this, we can see that we can’t compare and forward based on bearing type for an
alternative solution, because conceptually it can’t be known whether it is suitable or not for
 the gearbox before designing.so this project’s alternative solutions are based on shaft
alignment. There are three shaft alignments listed below:

a. Vertically aligned shaft

It’s one type of the shaft alignment, where the shaft stood vertically (upward and downward). In
this case the gears (pinion and the gear) mesh horizontally. The input shaft and output shaft is
parallel.

Vertically aligned shaft

b. Horizontally aligned shaft

It’s the other type of the shaft alignment, where the shaft stood horizontally (left and right). In
this case the gears (pinion and the gear) mesh vertically. The input shaft and output shaft is
parallel.
c. Eccentrically aligned shaft

It’s the other type of the shaft alignment, where the shaft stood horizontally (left and right). In
this case the gears (pinion and the gear) mesh vertically. The input shaft and output shaft is
offset.
3.6. Basic structure

As stated earlier the gearbox is a 2-stage reduction spur gearbox in the application
area of Blenders. This gearbox can perform in different ways, due to these three
alternative solutions had been forwarded to be selected. After assessing this three
alternative solutions, solution 1 is selected by the concept screening and scoring
method. Now this alternative idea is improved based on its function and needed
function.

SHAFTS
 Input shaft (shaft 1): it is a shaft which connects with the power source (motor) directly.
It contains the first pinion which connects it to the first gear. It runs at the motor speed
and give power to the first gear for reduction.
 Middle shaft (shaft 2): carries the first gear and the second pinion.
 Output shaft (shaft 3): it is the shaft which runs at the blades speed. It carries power from
gears and according to the gear ratio, it has an increased torque and reduced speed.
GEARS
Gears are used to transmit the power from one shaft to another. The gears in this case are spur
gears meshed horizontally in-line with different teeth numbers to attain the desired reduction
ratio based on the gear ratio. The gear ratio is the ratio of the driven gear teeth to the driving gear
teeth. If gear ratio is large than one, the input shaft revolves at lower speed than the output shaft
and the torque of the input shaft is higher than the output shaft. On other hand if the gear ratio is
less than one, than the input shaft revolves at higher speed than the output shaft and the torque of
the input shaft is lower than the output shaft.

CASING
To minimize size and weight and allow a good lubrication, cooling of the gear box a compact

casing made of light heat (thermal resistant) material is used.

BEARINGS
A machine element that constrains relative motion to only the desired motion, and reduces
friction between moving parts.

3.7. Functional analysis

Shafts

A shaft is a rotating machine element, circular in cross section, which is used to transmit
powerfrom primary power source to output, or from a machine which produces the power to a
machine or part (subsystem) which absorbs power
Gears
Spur gears, are formed by cutters that produce a straight that allows several teeth to mesh
simultaneously Spur gears are superior to other gears in their efficiency and cost effectiveness .
Lubrication and cooling system
Like other types of rotating equipment, gearboxes rely on lubrication to reduce friction and
provide cooling for optimal operation and life. Gearbox manufacturers provide recommendations
for the type of lubrication to be used and the typical lubrication intervals, but the actual gearbox
lubrication requirements depend on the environmental conditions the gearbox is exposed to,
whether it is properly maintained, and whether it experiences overloading. There are several
methods of lubrication like grease lubrication, oil splash lubrication, forced oil lubrication. But
for the purpose of spur gearbox an oil splash lubrication is recommended.
 CHAPTER FOUR
DETAIL DESIGN
In planning the gearboxes, the primary standards are to keep them straightforward, less weight
and at the equivalent time to keep the expense as low as could be expected. Thus, the weight and
cost have their separate weight age during the plan to such an extent that both the boundaries
could be sufficiently worth. The machinability is another significant thought.

There are some processes to accomplish this detail design completely. This are:

 Geometrical analysis and mathematical simulation

 Force analysis
 Stress and strength analysis

4.1. Working principle

The two stage reduction gearbox consists of three shafts and four gears (two driver gears, two
driven gears). The driver gear of the first stage of reduction which is probably the smallest gear
in the entire reduction gear box is present on the input shaft which gets the input from the motor
(power source). And the second shaft also called as the intermediate (middle) shaft consists of
the driven gear of the first stage of reduction and also the driver gear of the second stage of
reduction which are termed to be as compound gears. Finally, the third shaft called as the output

Shaft consists of the driven gear of the second stage of reduction which could be the largest gear.
This output shaft delivers the required rpm to the blades of the blender.

When the specified amount of RPM is given as an input to the driver gear of the first stage of
reduction, it starts rotating in a particular direction by causing a rotational moment on the driven
gear of the first stage of reduction. This happens as the teeth of the gears are engaged with each
other and the teeth of the pinion (driver gear) exert some force on the teeth of the gear (driven
gear). Now, as the driven gear of the first stage of reduction is in compound connection with the

Driver gear of the second stage of reduction, it also starts to rotate causing its teeth to apply some
rotational force on the teeth of driven gear of the second stage of reduction.

4.2. Geometrical analysis

Geometric analysis is a mathematical discipline where tools from differential equations,
especially elliptic partial differential equations are used to establish new results in differential
geometry of the given object.

Gear Profile Parameters:

Gear dimensions are determined in accordance with their specifications, such as Module (m),
Number of teeth (z), Pressure angle (α), and Profile shift coefficient (x). This section introduces
the dimension calculations for spur gear pairs. Calculations of external dimensions
(e.g.Tipdiameter) are necessary for processing the gear blanks. Tooth dimensions such as root
diameter or tooth depth are considered when gear cutting
Type of gears used: SPUR GEARS
The following the parameters required to obtain the required gear profile.

• Number of teeth

• Module

• Gear Ratio

• Circular Pitch

• Diametric Pitch and Pitch Circle Diameter

• Addendum and addendum circle Diameter

• Dedendum and dedendum circle Diameter

• Centre Distance

• Clearance

• Face width

Gear size, pressure angle, number of teeth…we introduce the basic terminology, measurement,
and relational expressions necessary to understand basic gear technology.

There are three standard systems for the shape of gear teeth. They are as follows:

 14.5° Full Depth Involute System

 20° Stub Involute System
 20° Full Depth Involute System

4.3 Number of teeth

Number of teeth denotes the number of gear teeth. A gear tooth has involute profile only outside
the base circle. In fact, the involute profile begins at the base circle. In some cases, the dedendum

is so large that it extends below this base circle. In such situations, the portion of the tooth below

The base circle is not involute. The tip of the tooth on the mating gear, which is involute,
interferes with this non-involute portion of the dedendum. This phenomenon of tooth profiles
overlapping and cutting into each other is called ‘interference’. In this case, the tip of the tooth
overlaps and digs into the root section of its mating gear. Interference is non-conjugate action
and results in excessive wear, vibrations and jamming.

Interference is the main disadvantage of involute gears. It is maximum when the smallest pinion
is in mesh with the largest gear. To eliminate interference, Increase the number of teeth on the
Pinion is mandatory. Increasing the number of teeth increases the size of the gearbox and also
increases the pitch line velocity. This is not desirable. The minimum number of teeth to avoid
interference and undercutting is as follows:

 For 14.5° full depth system 32 teeth

 for 20° full depth system 18 teeth
 For 20° stub system 14 teeth

So depending on this a tooth no of greater than 18 should be selected for the pinion to be
designed. The gearbox is a two stage reduction gearbox with spur gears in the application area of
blenders. So using a gear ratio of 3.5 with two stages. it becomes square root of 3.5

zg
√GR= zp => ᵶ𝑔= ᵶ𝑝 ∗ √3.5 = 24*√3.5 => ᵶ𝑔= 45 no. of teeth.

rotation of driven gear

Gear-ratio(R) =
rotation of driver gear

Then we have GR=3 this means while driver gear is rotated 3 times at the same time driven gear
is rotated 1 time.

Zg
√ GR= Zp

Zg
3.5= Zg= ( √ 3.5 ∗21 ) =40 tooth
22

To calculate center distance formula:

(d 1+d 2) m(Zg+ Zp)

a= =
2 2
 C 1
m= , m=
Dp Dp

0.25
Dp= =0.25 mm
1

1
m= =4
0.25

4 (40+21)
a= =122 mm
2

D 1=( m ∗ Zp )

D 1=( 4 ∗21 ) =84 mm

D 2=( m ∗ Zg )

D 2=( 4 ∗ 40 )=160 mm
Pitch = πm
pitcℎ= ( π ∗ 4 )=12.566 mm

Tooth depth,(h) =( 2.25 ∗ m)

ℎ=( 2.25 ∗ 4 )=9 mm
Addendum (ha):- It is the distance between the reference line and the tooth tip

ha=( 1.00 m )

ha=( 1.00 ∗ 4 )=4 mm

Dedendum (hf):- It is the distance between the reference line and the tooth root. hf =( 1.25 m )

hf =( 1.25∗ 4 )=5 mm

Tooth thickness (s):- It is basically half the value of pitch (p) s= ( πm/2 )

s= ( π ∗ 4 /2 )=6.283
Tip diameter (da)
d a=( d +2 m )

d a=( 84+ 2∗ 4 )=92 mm

Root diameter (df)

df =( d −2.5 m )

df =( 84 − 2.5∗ 4 )=74 mm
Width of the gear tooth b=( 8 ∗ m )

b=( 8 ∗ 4 )=32 mm

The two gear ratios are made equal. Therefore, the individual gear ratios are found by:
( GRi )= √3.5=1.87 Where i=1, 2, 3…
( GR 1 )=√ 3.5=1.87
( GR 2 )=√ 3.5=1.87
This means the gear ratio one * gear ratio two GR=√ 3.5 ∗ √ 3.5=3.5
To compute the design of torque that we have known formula
2 πnT 60 P
P= , T=
60 2 πn
Were
1horse power =746watts
7horse power =5222watts

60 ∗7 ∗ 746
Ti= =19.9465 ≈ 20 N . m
2 π 2500

GR= ¿ =3.5→ ¿=( Ti∗ GR )

Ti
¿=( 20 ∗3.5 ) =70 N . mm
As all of us knows this below formula:
input gear velocity output power output gear teeth
Gear-ratio(R) = = =
output gear velocity input power input gear teeth
To find more torque by calculating to reducing the speed given;

First reduction
GR= ¿
No
2500
No= ¿ → No= =1336.3062rpm
GR √3.5

¿=( Ti∗ GR )

¿=( 20 ∗√ 3.5 )=37.41 N.mm

Second reduction
1336.3062
No= ¿ → No= =714.286 rpm
GR √3.5

¿=( Ti∗ GR )

¿=( 37.41∗ √ 3.5 )=69.988 N . mm ≈70 N . mm

Force analysis
Given Specifications and data:
 GR)= 3.5
 Np = 2500 rpm
 Pi = 7hp
 Zp1=Zp2 =21 no. of tooth
 Zg1=Zg2 =40 no. of tooth
 m=4mm
 b=32mm
 df=74mm
 da=92mm
 s=6.283mm
  ha=4mm
 hf=5mm
 pitch=12.566mm
First reduction
This reduction is between the first pinion and the first gear.
(d 1+d 2) (84 +160)
a= → a= =122 mm
2 2
Step 1: The Torque acting on the gears
6
60∗ 10 ( KW )
Mt 1=
2 πNp 1

6 −3
60∗ 10 ∗5222 ∗10
Mt 1= =19946.5 ≈20,050 N . mm
2 π ∗2500

Step 2: The Tangential force acting on the gears

dp
Mt 1=Pt 1∗
2
2 Mt 1
Pt 1=
dp
2∗ 20,050
Pt 1= =477.3 ≈ 477 N
84
Step 3: The Radial force acting on the gears
Pr 1=Pt 1∗ ( tan α )

Pr 1=477 ∗ ( tan 20 ° )=173.6 N ≈ 174 N

Second reduction
Step 1: The Torque acting on the gears
6
60∗ 10 ( KW )
Mt 2=
2 πNp 2
6 −3
60∗ 10 ∗5222 ∗10
Mt 2= =37,325.169 Nmm ≈ 37,326 N . mm
2 π ∗ 1336.3062
Step 2: The Tangential force acting on the gears
dp
Mt 2=Pt 2∗
2
 2 Mt 2
Pt 2=
dp
2 ∗37,326
Pt 2= =888.7 ≈ 889 N . mm
84
Step 3: The Radial force acting on the gears
Pr 2=Pt 2∗ ( tan α )

Pr 2=889 ∗ ( tan 20° )=323.56 N ≈ 324 N

4.4 Gear Materials

The material used for the manufacture of gears depends upon the strength and service
conditions like wear, noise etc. The gears may be manufactured from metallic or non-metallic
materials. The metallic gears with cut teeth are commercially obtainable in cast iron, steel and
bronze. The nonmetallic materials like wood, rawhide, compressed paper and synthetic resins
like nylon are used for gears, especially for reducing noise.
The cast iron is widely used for the manufacture of gears due to its good wearing properties,
excellent machinability and ease of producing complicated shapes by casting method. The cast
iron gears with cut teeth may be employed, where smooth action is not important.
The steel is used for high strength gears and steel may be plain carbon steel or alloy steel.
The steel gears are usually heat treated in order to combine properly the toughness and tooth
hardness.

The phosphor bronze is widely used for worm gears in order to reduce wear of the worms which
will be excessive with cast iron or steel. The following table shows the properties of commonly
used gear materials.

To select a material, the bending stress should be found so, from the above stated theories of
Buckingham and Lewis, the bending stress σb is:

Cs is taken as 1

Factor of safety of 2.5

Bending stress
 (KW )∗Cs ∗ fs
σ b=60 ∗10 6 ∗
b
π ∗ Zp ∗np ∗ Cv ∗ Y ∗ m3
m
πdn
Cv varies depending on the velocity V of the gear. V = 3
60 ∗10
π ∗84 ∗ 2500
V= 3
=10.99 m/s ≈11 m/s
60 ∗10
We know that for ordinary cut gears and operating at velocities upto 12.5 m/s, the velocity
factor,
3
C v= .
3+V
3
C v= =0.214
3+11
The Lewis factor Y from the table for a 21 No. of pinion teeth is 0.328.
−3
6 5222∗ KW ∗ 10 ∗1 ∗ 3 2
σ b=60 ∗10 ∗ =158.6 N /mm
32 3
π ∗21 ∗2500 ∗ 0.214 ∗ ∗ 0.328 ∗ 4
4
Ultimate strength

S ut
σ b=
3
2
Sut =( 158.6 ∗3 ) =475.9 N /mm

.
Carbon steel of Grade 200-400 has been selected for the designing of the gear due to its ease of
machinability, cost, Hardness and approximation to the calculated ultimate tensile strength.
Stress analysis

So, Stress analysis for gear teeth is regarded as a limiting factor. Stress analysis focuses on the
determination of the regions of stress concentration where failure or fracture may be initiated.

(a) Stress due to Static load (beam strength)

The allowable static stress for steel gears is approximately one-third of the ultimate tensile
S ut
strength σ b=
3
 400
σ b= =133 N /mm
3

Step 1: Beam strength

S b=( m∗ b ∗ σ b ∗Y )

S b=( 4 ∗ 32∗ 133 ∗0.328 )=5583.9 N ≈5584 N

6
60∗ 10 ( KW )
Step 2: Tangential force due to rated torque Mt 1=
2 πNp 1

6 −3
60∗ 10 ∗5222 ∗10
Mt 1= =19946.5 ≈20,000 N . mm
2 π ∗2500

Since, The Torque acting on the gears

dp 2 Mt 1
Mt 1=Pt 1∗ → Pt 1=
2 dp

2∗ 20,050
Pt 1= =477.3 ≈ 477 N
84

Step 3: Effective load

We have the results of:

5m 3
V=11. according to this we have the value of Cv= C v = =0.35
s 3+11

1 ∗ 477
Peff = =2228.97 N ≈ 2229 N
3
3+ 11

Step 4: Factor of safety due to beam strength (static load)

sb
f s=
Peff
 5584
f s= =2.505 The design is safe.
2229

4.5 Design of Shaft

A shaft is a rotating machine element which is used to transmit power from one place to another.
The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft. In order to transfer the power from one shaft to another, the various members
such as pulleys, gears etc., are mounted on it. These members along with the forces exerted upon
them causes the shaft to bending. In other words, we may say that a shaft is used for the
transmission of torque and bending moment. The various members are mounted on the shaft by
means of keys or splines.

4.5.1 Material Used for Shafts

The material used for shafts should have the following properties :
 It should have high strength.
 It should have good machinability.
 It should have low notch sensitivity factor.
 It should have good heat treatment properties.
 It should have high wear resistant properties.
The material used for ordinary shafts is carbon steel of grades 40 C 8, 45 C 8, 50 C 4 and 50 C
The mechanical properties of these gra

Standard Sizes of Transmission Shafts

The standard sizes of transmission shafts are:
25 mm to 60 mm with 5 mm steps; 60 mm to 110 mm with 10 mm steps ; 110 mm to 140 mm
with 15 mm steps ; and 140 mm to 500 mm with 20 mm steps.
The standards lengths of the shafts are 5 m, 6 m and 7 m

Maximum Permissible Working Stresses for Transmission Shafts

According to American Society of Mechanical Engineers (ASME) code for the design of
transmission shafts, the maximum permissible working stresses in tension or compression may
be taken as
 112 MPa for shafts without allowance for keyways.
 84 MPa for shafts with allowance for keyways.
For shafts purchased under definite physical specifications, the permissible tensile stress (σt)
may be taken as 60 per cent of the elastic limit in tension (σel), but not more than 36 per cent of
the ultimate tensile strength (σu). In other words, the permissible tensile stress,
σt = 0.6 σel or 0.36 σu, whichever is less.
The maximum permissible shear stress may be taken as
 56 MPa for shafts without allowance for key ways.
 42 MPa for shafts with allowance for keyways.

4.5.2 Design of Shaft for Spur Gears

In order to find the diameter of shaft for spur gears, the following procedure may be followed.
First of all, find the normal load (WN), acting between the tooth surfaces. It is given by
WN =WT /cos φ
Were
T= Twisting moment (or torque) acting upon the shaft,
J = Polar moment of inertia of the shaft about the axis of rotation,
τ = Torsional shear stress, and
D is the diameter of the shaft.
TG = No. of teeth on the gear,
b = Face width in mm, and
m = Module in mm.
WT = Tangential load, and
φ = Pressure angle.
A thrust parallel and equal to WN will act at the gear center
 The weight of the gear is given by
WG=0.00118 TG . b . m2(¿ N )
Were
T= Twisting moment (or torque) acting upon the shaft,
J = Polar moment of inertia of the shaft about the axis of rotation,
τ = Torsional shear stress, and
D is the diameter of the shaft.
TG = No. of teeth on the gear,
b = Face width in mm, and
m = Module in mm.
WT = Tangential load, and
φ = Pressure angle.

Now the resultant load acting on the gear,

√ 2 2
W R= ( W N ) + ( W G ) + 2W N +W G cos ∅

 If the gear is overhung on the shaft, then bending moment on the shaft due to the
resultant load,
 M =WR × x
 x = Overhang i.e., the distance between the Centre of gear and the Centre of bearing.
 Since the shaft is under the combined effect of torsion and bending, therefore we shall
determine the equivalent torque. We know that equivalent torque,
 T e =√ M 2 +T 2
 T = Twisting moment = WT × DG /2
 Now the diameter of the gear shaft (d) is determined by using the following relation,
i.e.
π
 T e= ∗τ∗d
16
 τ= Shear stress for the material of the gear shaft.
 NB Proceeding in the similar way as discussed above, we may calculate the diameter
of the pinion shaft.
 Given specification
GR 3.5

Np 2500 rpm
Pi 7hp
Zp1=Zp2 21 no. of tooth
Zg1=Zg2 40 no. of tooth
m 4mm
b 32mm
df 74mm
da 92mm
s 6.283mm
ha 4mm
hf 5mm
pitch 12.566mm

Force analysis

The power is delivered to the shaft by some tangential force and the resultant torque (or twisting
moment) set up within the shaft permits the power to be transferred to various machines linked
up to the shaft.

 Vertical load
In order to this we depend the pt1 @ pt2
The moments at point A and B
M @ point A
 → Pr 1 ∗ L 1+ Pr 2 ∗ L=RvB ∗(L 2+ L 3)

(174 ∗50)+(324 ∗ 84)

RvB =268.02 N ≈ 268 N
134
M @ point B
P r 1+ P r 2=R BV + R AV

R AV =P r 1+ P r 2 − R BV

R AV =174+ 324 −268=230 N

M AV =M BV =0
Bending moment @ C
M AV =RvB ∗ L1

M CV =230∗ 50=11500 N .mm

Bending moment @ D
M DV =RBV ∗ 40
M DV =268∗ 40=10720 Nmm

 Horizontal load
In order to this we depend the pt1 @ pt2
The moments at point A and B
M @ point A
→ Pt 1 ∗ L 1+ Pt 2 ∗ L=RHB ∗( L 2+ L3)
(477 ∗50)+( 889∗ 84)
RHB =735.26 N
134
M @ point B

P t 1+ P t 2=R BH + R AH

R AH =Pt 1+ P t 2 − R BH

RA H=477+889 −735.26=630.74 N

M AH =M BH =0
Bending moment @ C
M CH =RBH ∗ L 1

M CH =735.26 ∗50=36763 N . mm
Bending moment @ D
M DH =RBH ∗47

M DH =735.26 ∗ 40=29410.4 NNmm

Resultant B.M. at C
MC= √ ( MCV )2 +(MCH )2

MC= √ (11500)2+(36763)2=38519.71 Nmm

Resultant B.M. at D
MD=√ ( MDV )2+(MDH )2

MD=√ (10720)2 +(29410.4 )2 =31303.2 Nmm

Bending moment is maximum at D.
Maximum bending moment
M =M D

M =31303.2

T e =√ (31303.2)2+(20,000)2=37146.87 ≈ 37147 Nmm

π 3
T= ∗ τ ∗d
16
Where: -
T= Twisting moment (or torque) acting upon the shaft,
J = Polar moment of inertia of the shaft about the axis of rotation,
τ = Torsional shear stress, and
D is the diameter of the shaft.
TG = No. of teeth on the gear,
b = Face width in mm, and
m = Module in mm.
WT = Tangential load, and
 3 16 T
d=
π ∗τ

d=
√
3 16 T
π∗τ
→
√
3 16 ∗ 20,000

π ∗ 46
=16.52 ≈ 20 mm a ccording standard of ASME

4.6 Design of key

A key is a piece of mild steel inserted between the shaft and hub or boss of the pulley to connect
these together in order to prevent relative motion between them. It is always inserted parallel to
the axis of the shaft. Keys are used as temporary fastenings and are subjected to consider able
crushing and shearing stresses. A keyway is a slot or recess in a shaft and hub of the pulley to
accommodate a key

4.6.1 Types of Keys

The following types of keys are important from the subject point of view:
 Sunk keys,
 Saddle keys,
 Tangent keys,
 Round keys, and
 Splines.
Square sunk key. The only difference between a rectangular sunk key and a square sunk key is
that its width and thickness are equal, i.e.

w=t=d /4

Given specification
 GR= 3.5
 Np = 2500 r/m
 No=714.286 r/m
 Pi = 7hp
 Zp1=Zp2 =21 no. of tooth
 Zg1=Zg2 =40 no. of tooth
Force analysis
Torque transmitted by the shaft
 First reduction
6
60∗ 10 ( KW )
Mt 1=
2 πNp

6 −3
60∗ 10 ∗5222 ∗10
Mt 1= =19946.5 ≈20,050 N . mm
2 π ∗2500
6
60∗ 10 ( KW )
 Second reduction Mt 1=
2 πNp
6 −3
60∗ 10 ∗5222 ∗10
Mt 1= =70000 Nmm
2 π ∗714.2
Force acting on key
First stage pinion and gear
 On pinion
dp
M t 1=P k
2
2 M t 1 2 ∗ 20,050
Pk = = =477 N
dp 84
 On gear

dg
M t 1=P k
2
2 M t 1 2 ∗ 20,050
Pk = = =250.6 N
dp 160
Second stage pinion and gear
 On pinion
dp
M t 1=P k
2
2 M t 1 2 ∗7 0000
Pk = = =1666.6 N
dp 84
 On gear
 dg
M t 1=P k
2
2 M t 1 2 ∗70,000
Pk = = =875 N
dp 168

Material selection
The material should have resistance to corrosion and relatively low cost and weight. The plain
carbon steel 40C8 is selected from cost, weight and corrosion resistant aspects.
According to Carbon steel 40C8 is selected:

Sut=580N/mm
Syt=380N/mm
Permissible compressive stress
Syc=Syt=380 N /mm
Syc
σc=
fs
380
σc= =127 N
3

Permissible shear stress

2
Syc=0.5 Sy t=290 N mm
290 2
τ= =97 N /mm
3
According to square key there is the standard proportion formula;
Width = height=d/4
20
w=d =5 mm
4
Length of key depending on shear stress

2 Mt
l=
τ ∗d∗b

2 ∗70,000
l= =14 mm
97 ∗5 ∗5

Length of key depending on compressive/crushing stress

2 Mt
l=
σc ∗ d ∗b

2 ∗70000
l= =5.5 mm
127 ∗5 ∗ 5

From the above calculation, the length of the key is 14mm.

4.7 Design of housing
Gearbox casing is the one which will hold mechanical components of a transmission.

Given specification

 a=122mm
 ds=20mm
 l=134mm
 d1=84mm
 d2=160mm
Material selection

Cast iron

 easy to manufactured
 it has good strength
 corrective resistance
Force analysis the moments at point A and B
M @ point A
→ Pr 1 ∗ L 1+ Pr 2 ∗ L=RvB ∗(L 2+ L 3)

(174 ∗50)+(324 ∗ 84)

RvB =268.02 N
134
M @ point B
P r 1+ P r 2=R BV + R AV

R AV =P r 1+ P r 2 − R BV

R AV =174+ 324 −268.02=229.98 N ≈ 230 N

M AV =M BV =0
Bending moment @ C
M AV =RvB ∗ L1

M CV =230∗ 50=11500 N .mm

Bending moment @ D
 M DV =RBV ∗ 47

M DV =268.02∗ 50=13401 N .mm

 Horizontal load
In order to this we depends the pt1 @ pt2
The moments at point A and B
M @ point A
→ Pt 1 ∗ L 1+ Pt 2 ∗ L=RHB ∗(L 2+ L3)

(477 ∗50)+( 889∗ 84)

RHB =735.3 N
134
M @ point B
P t 1+ P t 2=R BH + R AH

R AH =Pt 1+ P t 2 − R BH

RA H=477+889 −735.3=630.7 N

M AH =M BH =0
Bending moment @ C
M CH =RBH ∗ L 1

M CH =630.7 ∗50=31535 N . mm
Bending moment @ D
M DH =RBH ∗50

M DH =735.3 ∗ 50=36765 Nmm

Internal width of housing

2*gear width + 2*bearing width+1*4+thickness of house partition

2 ∗32+2 ∗20+ 4+ 20=128 m m

Internal length of housing

 128+2 ∗ 85+2=300 mm

Problem statement:

Mounting points must provide stability by adding reaction forces to the structure, resulting force
flow paths, but also to accommodate shock absorbing which provides damping action. The
flange part is a connection between the motor and the rest of the housing and it is assumed that
the entire-counter torque is provided through it and the housing structure. On the back side is the
oil inlet and outlet located and on the front side, there is the control mounting point.

One of the output gear bearings is axially ensured by a bearing cap. The cap takes the axial
forces of the output gear upon the housing structure.

To summarize, the gearbox design is created according to the following design considerations:

 Lightweight and mass distribution: minimizing weight is vital. Keeping the mass
center as close as possible to the mid plane and as low as possible in the overall
assembly.
 Strength towards applied loads includes contact strength in the faces / areas of contact
like
 the bearing beds, bolt joints etc. Lifetime in accordance to fatigue accumulation
estimation
 Oiling system – preserve the oil, minimum squashing and wall dipping effects;
accessible
 oil inlet on highest point and drain at the lowest.

Material selection

Mostly gearboxes are made of cast iron because of their wide application. The gearbox designed
in this study is of a blender application, so it should be strong, rigged and light weight. These
properties can be found on cast Iron as it is easily machined, strong and corrosive resistant.Grey
cast iron is used for automotive components such as cylinder block, brake drum, clutch plate,
cylinder and cylinder head, gears and housing of gear box, flywheel and, bed and guide.
Property of grey cast Iron FG350:

 Ultimate tensile strength - 𝑆𝑢𝑡 = 350 𝑁 𝑚𝑚2 ⁄

 Hardness – 207-241
 CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION

This paper has centered on modeling and investigation of two organize decrease goad gearbox
with emphasis on lightweight, issue understanding, transportability and straightforward
accessibility of the fabric and as well as on moo beginning, operational and upkeep taken a toll.
This venture is valuable for blender application.

The major components and parameters such as bearing estimate, jolt estimate, body width and
thickness, gear measure and connected drive were chosen effectively by considering the
application range and, purpose of the chosen fabric.

In this gearbox the gear has 45 teeth, and pinion 24 teeth. The gear and pinion has a pitch
diameter of 180 and 96mm respectively. This spur gearbox will have an output speed of
714.3rpm

And the materials have to be safer because this bending machine must resist the cold effect and
any changing weather conditions. It must be corrosion resistant.