Executive Summary

This report is the culmination of an in-depth analysis aimed at meeting the customer's specific
requirements for an industrial gearbox. The gearbox has been engineered to efficiently handle a
power input of 2 kW while maintaining a steady-state input speed of 2100 rpm and an output speed
of 150 ± 1 rpm. The design is tailored to ensure a lifespan of 10 years, accommodating continuous
operation for 7.5 hours a day, five days a week, with a maximum allowable failure rate of 2%.

A thorough examination of the existing literature was undertaken to integrate the most recent studies
and advancements in gearbox design, Finite Element Analysis (FEA) of gearing systems, and
sophisticated maintenance approaches that are relevant to gearboxes. The design choices were driven
by these observations, resulting in a solution that is resilient and trustworthy.

For the facilitation of the planning process, certain assumptions were made to streamline calculations
without compromising the integrity of the gearbox's performance. The resultant specifications for
gearbox components have been meticulously outlined, providing a clear roadmap for manufacturing.

Detailed shaft and gearbox layout drawings have been included for easy reference in the 'detailed
drawing' section, offering a visual representation of the proposed design. This comprehensive
approach addresses the specific customer requirements and sets the stage for a high-performing,
durable gearbox that aligns seamlessly with the company's commitment to excellence.
Contents
Executive Summary................................................................................................................................. 1
1. Introduction .................................................................................................................................... 5
2.1 Objectives...................................................................................................................................... 5
2. Literature Review ............................................................................................................................ 5
2.1 Design and Analysis of Gearboxes ................................................................................................ 5
2.1.1 Gear Tooth Profile Optimization ............................................................................................ 5
2.1.2 Material Selection and Strength Analysis .............................................................................. 6
2.1.3 Efficiency Enhancement Techniques ..................................................................................... 6
2.1.4 Integration of Advanced Materials and Manufacturing Techniques ..................................... 6
2.2 Types of Gearboxes and Their Applications .................................................................................. 6
2.3 FEA of Gearing Systems ................................................................................................................ 7
2.4 Maintenance Techniques for Gearboxes ...................................................................................... 8
2.5 Root Cause Analysis of Gearbox Failures ...................................................................................... 8
References ............................................................................................................................................ 26
List of Tables
Table 1 Design Parameters ................................................................................................................... 18
Table 2 Shafts speed ............................................................................................................................. 19
Table 3 Bearing properties .................................................................................................................... 24
Table 4 Key Dimensions ........................................................................................................................ 24
Table 5 Tolerance limit.......................................................................................................................... 25

List of Figures
Figure 1: parallel helical gears .............................................................................................................. 10
Figure 2 Transmission shaft .................................................................................................................. 19
Figure 3 Two-stage speed reduction configuration .............................................................................. 20
Figure 4 ball-bearing ............................................................................................................................. 22
Figure 5 Shaft keyway and key.............................................................................................................. 24
symbol Meaning units
𝑁𝑖𝑛 Input Speed rpm
𝑁_𝑜𝑢 Output Speed rpm
V.R. Velocity Ratio -
z Number Of Teeth -
σ1 Endurance Stress MPa
𝒀𝒗 Lewis’ Factor -
σb Bending Stress MPa
m Module mm
𝑀𝑡 Bending Moment Nm
𝜑 degree
σc Surface Stress MPa
σ𝑖𝑛𝑑𝑢𝑐𝑒𝑑 Induced Stress MPA
𝛽 Helix Angle degree
𝐶𝑣 Barth Velocity Ratio -
T Torque Nm
𝜏𝑠 Torsional Stress MPa
𝑆𝑒 Shaft Endurance
C Basic Dynamic Load Rating N
P Load N
𝐾.𝑅. Reliability Factor -
L Fatigue Life millions of revolutions
 1. Introduction
The field of manufacturing machinery places significant emphasis on the critical importance of
precision and reliability. This study aim to establish a design for an industrial gearbox that both meets
the rigorous requirements of clients and represent a commitment to achieving engineering
superiority. The main objective of this project is to develop a gearbox that offers high performance
efficient and durable.

1.1 Objectives
• Design the gearbox for uniformly loaded applications.
• Establish gearbox design procedure.
• Develop practical gearbox design proposal.
• Ensure an expected operational lifespan of 10 years.
• Minimize energy loss while ensuring practical power transmission from source to application.

2. Literature Review
To enhance improvements in the development of an efficient gearbox, it is important to undertake a
comprehensive analysis of relevant academic literature and significant breakthroughs in the field of
gearbox technology. The present literature study offers a comprehensive assessment of the
methodologies employed in the design of gearboxes, the analytical techniques utilized for their
analysis, the various classifications used to categorize them, and the wide range of applications in
which they are extensively employed.

2.1 Design and Analysis of Gearboxes

The design and analysis of gearboxes play a critical role in achieving maximum performance and
durability in industrial machines. This specific discipline encompasses a comprehensive methodology
that integrates various elements, including the examination of gear tooth profiles, material selection,
and strength assessment.

2.1.1 Gear Tooth Profile Optimization

The optimization of gear tooth profiles plays a critical role in the design of gearboxes. Accurate
identification of tooth properties, including pitch, profile, and addendum, is important for the purpose
of enhancing power transmission effectively and reducing tooth deterioration. The academic research
conducted by Vilmos Simon in 2017 offers significant and necessary perspectives on this particular
approach.

2.1.2 Material Selection and Strength Analysis

The selection of appropriate materials for gearbox components is of utmost importance in order to
endure the demanding conditions of operation. The significance of materials with high fatigue
strength, wear resistance, and suitable heat treatment capabilities is emphasized in the research
conducted by H. Delibaş, Ç. Uzay, and N. Geren (2017) in this particular field. Through the application
of extensive strength analysis on gearbox components, engineers may ascertain that the chosen
materials satisfy or surpass the required load-bearing capacities, hence augmenting the overall
dependability and durability of the gearbox.

2.1.3 Efficiency Enhancement Techniques

Efficiency is a critical consideration in gearbox design, as it directly impacts energy consumption and
system performance. Scholars like Christian and Jacobs (2020) and Jing LI (2016). explore techniques
such as profile modification, surface finish optimization, and lubrication strategies to minimize losses
due to friction and improve overall efficiency. Through careful implementation of these techniques,
engineers can significantly reduce energy dissipation, leading to more economical and sustainable
gearbox operation.

2.1.4 Integration of Advanced Materials and Manufacturing Techniques

Recent research on gearbox design has seen a significant rise in the exploration of novel materials like
as composites and high-strength metals, along with the adoption of additive manufacturing
techniques. The aforementioned advancements, as investigated by modern scholar Kapil Gupta
(2018), have the capacity to transform the field of gearbox design. This is achieved through the
provision of materials with enhanced strength-to-weight ratios, as well as the facilitation of intricate
designs that were previously unachievable. The inclusion of this technology holds the potential to
significantly improve the performance and efficiency of gearboxes.

2.2 Types of Gearboxes and Their Applications

The wide range of gearbox layouts is indicative of the complex and diverse requirements found in
various industrial applications. Gearbox technology has remarkable adaptability across numerous
industries, as each form of gearbox fulfills specific tasks and finds its place (Saif M 2023).

• Helical Gearboxes: Helical gears, characterized by their slanted tooth orientation, offer
smooth and quiet operation. They find widespread use in applications requiring high torque
transmission, such as conveyors and elevators. Additionally, their efficiency and compact
design make them well-suited for automotive transmissions.
 • Bevel Gearboxes: Bevel gears, with their conical shape, facilitate the transmission of power
between intersecting shafts. This configuration excels in applications demanding right-angle
power transmission, such as in differential mechanisms of vehicles and machinery used in
woodworking.
• Planetary Gearboxes: Planetary gearboxes are essential in applications that require high gear
reduction ratios due to their small and extremely efficient construction. These gear
arrangements, play a vital role in several industries; robotics, wind turbines, and aircraft.
• Worm Gearboxes: Worm gears offer excellent gear reduction capabilities and are commonly
used in applications requiring high torque outputs, such as lifts and conveyor systems. Their
self-locking feature makes them ideal for applications where back-driving prevention is
crucial.
• Spiral Bevel Gearboxes: It combines the advantages of bevel and helical gears; spiral bevel
gearboxes excel in high-speed and high-torque applications. They are often employed in heavy
machinery, marine propulsion systems, and power transmission systems.
• Parallel Shaft Gearboxes: These gearboxes are known for their configuration of shafts that run
parallel to one other. These gearboxes exhibit versatility and are utilized across several
industries.
• Epicyclic Gearboxes: Epicyclic gearboxes, also known as to as sun-and-planet gears, possess
distinctive capabilities in facilitating intricate speed and torque regulation. They play a crucial
role in the functioning of automatic transmissions, wind turbine systems, and numerous
automobile applications.
• High-Speed Gearboxes: Mostly used in industries such as aerospace, automotive, and power
generation, where the requirement for high rotating speeds is critical. These objects have
been specifically designed to endure the immense forces and velocities that are typically
encountered in such settings.
• Low-Speed Gearboxes These gearboxes are specifically designed for applications that favor
torque rather than speed. They are utilized in the field of heavy machinery, such as mining
equipment, as well as in specialist domains like winches and cranes.

2.3 FEA of Gearing Systems

The utilization of Finite Element Analysis (FEA) in the examination of gear systems has become a crucial
technique in contemporary gearbox design. In a recent study conducted by Li and Chiou, advanced
finite element analysis (FEA) approaches were introduced to enhance the accuracy of predicting stress
distributions, deformation patterns, and fatigue life of gears across different operational situations.
The process of integration has resulted in the optimization of gear profiles, consequently making a
substantial contribution towards improving performance and durability.

2.4 Maintenance Techniques for Gearboxes

The implementation of dependable maintenance procedures is of the greatest importance in
prolonging the lifespan of gearboxes. Ryan Clancy (2023) offers an in-depth review of predictive
maintenance techniques, including vibration analysis, thermography, and oil analysis, providing
valuable insights into their application and effectiveness. These strategies facilitate the timely
identification of possible faults, hence mitigating downtime and guaranteeing continued operation.

2.5 Root Cause Analysis of Gearbox Failures

In order to develop strong and trustworthy systems, it is crucial to possess a full comprehension of
gearbox failures. The significance of root cause analysis is emphasized in the research conducted by
C.D. Nguyen and A. Prosvirin (2022), as well as other scholars. Their work offers several approaches
for the identification and resolution of failure spots. The adoption of a proactive approach plays a
crucial role in preventing the occurrence of repetitive problems, hence significantly improving the
overall lifespan of the gearbox.

3. Gearbox design
This phase entails a comprehensive analysis of the sophisticated design of the gearbox, which includes
a meticulous evaluation of all specified requirements and design factors. This process involves the
careful selection of appropriate gears, the calculation of optimal gear ratios, the organization of shafts,
and the verification of the gearbox's overall structural soundness.

Design requirements:

• Power output of 2kW

• Steady-state input speed 2100 rpm
• Steady-state output speed 150 + 1 rpm
• Base mounted with four bolts
• Life span of 10years

3.1 Gear selection

The gear selection process is a crucial phase in gearbox design, as it significantly influences the overall
performance, efficiency, and durability of the system. This phase involves a comprehensive evaluation
of several equipment options to choose the most suitable ones for the specific application.

3.1.1 Gear Type

a) Spur Gears:
Characteristics:
• Straight teeth aligned along parallel shafts.
 • They are known for simplicity, cost-effectiveness, and high efficiency.
Advantages:
• Simplicity in design and manufacturing.
• Cost-effective production.
• High mechanical efficiency.
Considerations:
• Potential for higher noise levels compared to helical gears.
• There is a higher risk of impact loading due to straight teeth engagement.
Suitable Applications:
• Where noise levels are not a critical concern.
• Cost-sensitive applications with high-efficiency requirements.
b) Helical Gears:
Characteristics:
• Angled teeth for smoother engagement and quieter operation.
• Well-suited for applications where noise reduction and high load-carrying capacity are
paramount.
Advantages:
• Quieter operation compared to spur gears.
• Better load distribution across teeth.
• Well-suited for high-load applications.
Considerations:
• Slightly lower mechanical efficiency compared to spur gears.
• More complex manufacturing process.
Suitable Applications:
• Environments where noise reduction is crucial.
• High-load applications require a smooth and reliable operation.
(https://www.mechanicaleducation.com/difference-between-spur-gear-and/)
From the comparison above, helical gear is selected.
 Figure 1: parallel helical gears

3.1.2 Power and Speed Requirements

Given Data:

Power to be delivered (output): 2 kW

Steady-state input speed: 2100 rpm

Steady-state output speed: 150 ± 1 rpm

Power Calculation:

Power output = 2 kW

speed requirements:

Speed Ratio Calculation:

The velocity ratio (𝑁) is defined as the ratio of input speed (𝑁𝑖𝑛 ) to output speed (𝑁_𝑜𝑢𝑡). It is
calculated as follows:

𝑁 = 𝑁𝑖𝑛 /𝑁_𝑜𝑢𝑡
Given:

𝑁𝑖𝑛 = 2100 rpm

𝑁_𝑜𝑢𝑡 = 150 rpm

Calculating the speed ratio:

𝑁 = 2100/150
𝑁 = 14
With a velocity ratio of 14, it becomes evident that a single stage of gear reduction may not suffice to
achieve the specified output speed of 150 ± 1 rpm. In addressing this requirement, a multi-stage gear
reduction system will be necessary.
In a multi-stage gear train, several sets of gears are strategically arranged to reduce the input speed
to the desired output speed gradually. Each stage provides a specific level of speed reduction, and
when combined, they collectively achieve the required speed reduction.
The design process will entail the selection of appropriate gear ratios for each stage within the gear
reduction system. Careful consideration will be given to the arrangement and sizing of gears to ensure
efficient power transmission and the compactness of the gearbox. If there are any specific preferences
regarding the number of stages or other design aspects, those will be taken into account as well.
For this design, speed requirement and gear type selected, a double-stage speed reduction is
considered.
The velocity ratio has been assumed to be the same for each stage to save on manufacturing time,
cost, and tool requirements. This configuration will allow two sets of equal gears.
𝑉𝑅1 = 𝑉𝑅2 = √𝑁

= √14
= 3.74
𝑁1
⁄𝑁 = 3.74
2

2100⁄ = 3.74
𝑁2
𝑁2 = 561.50 𝑟𝑝𝑚
Since gear 1 and pinion 2 are connected to the same shaft, they rotate at the same speed.

𝑁2 = 𝑁3 = 561.50 𝑟𝑝𝑚
Where;

𝑉𝑅1 = velocity ratio for the first stage gear reduction

𝑉𝑅2 = velocity ratio for the second stage gear reduction
𝑁1 = pinion 1 speed
𝑁2 = gear 1 speed
𝑁3 = pinion 2 speed
𝑁3 = gear 2 speed

3.1.3 system selection and strength calculation

The choice of a closed system for the purpose of ensuring uninterrupted lubrication and effective
management of abrasive wear is crucial. The chosen tooth system is a full-depth involute system with
a 20-degree angle.
a) Number of the teeth on the pinion
The minimal number of teeth on the pinion required to prevent interference is given by:
2𝑐𝑜𝑠𝛽
𝑧𝑚𝑖𝑛 =
𝑠𝑖𝑛2 𝛼
Helix angle (𝛽) ranges between 8𝜊 to 25𝜊
Taking helix angle (𝛽) of 16𝜊
 2𝑐𝑜𝑠16
𝑧𝑚𝑖𝑛 =
𝑠𝑖𝑛2 20
𝑧𝑚𝑖𝑛 = 16.43
Therefore,
𝑧1 = 17
𝑧2 = 𝑧1 × 𝑉𝑅1
𝑧2 = 17 × 3.74

𝑧2 = 63.58 ≈ 64
Where:
Z= number of teeth
b) Material selection
For, (https://gearsolutions.com/features/finding-the-ideal-materials-for-gears/)
o pinion- 303 stainless steel
o gear -304 stainless steel
Item Tensile Strength (MPa) Brinell Hardness
Pinion 690 228
Gear 505 123

c) Endurance limit (σ1)

For the pinion,
(σ1 ) = 0.35σ𝑢𝑡
(σ1 ) = 0.35 × 690
= 241.50MPa
For the gear,
(σ1 ) = 0.35σ𝑢𝑡
(σ1 ) = 0.35 × 505
= 176.75MPa
d) Calculation of the virtual number of teeth
The virtual number of teeth is used in helical gears to account for the effect of the helix angle on the
tooth engagement. It is calculated using the actual number of teeth and the helix angle.
This calculation is essential because the helix angle causes the teeth to be engaged over a longer
distance compared to spur gears. As a result, the load distribution and tooth strength characteristics
are affected.
(https://mmsallaboutmetallurgy.com/wp-content/uploads/2019/02/machine-design.pdf.pdf pg.751)
 𝑧1
𝑧𝑣1 =
𝑐𝑜𝑠 3 𝛽
17
=
𝑐𝑜𝑠 3 (16)
= 19.14

𝑧2
𝑧𝑣2 =
𝑐𝑜𝑠 3 𝛽

64
=
𝑐𝑜𝑠 3 (16)

= 72.05
e) Lewis form factor (𝒀𝒗 )
It is used to adjust the basic gear tooth strength calculations. It accounts for factors such as tooth
profile, material properties, and loading conditions.
For the pinion,
0.912
𝑌𝑣 = 𝜋(0.154 − )
𝑧𝑣1
0.912
𝑌𝑣 = 𝜋(0.154 − )
19.14

𝑌𝑣 = 0.33
For the gear,
0.912
𝑌𝑣 = 𝜋(0.154 − )
𝑧𝑣2
0.912
𝑌𝑣 = 𝜋(0.154 − )
72.05

𝑌𝑣 = 0.44
f) Weak element identification
Using the above strength calculation to identify the weaker element between the pinion and the gear.
σ1 × 𝑌𝑣
Pinion,
σ1 × 𝑌𝑣 = 241.50MPa × 0.33 = 79.70𝑀𝑃𝑎
Gear,
σ1 × 𝑌𝑣 = 176.75MPa × 0.44 = 77.77𝑀𝑃𝑎
Based on the computation above, it can be determined that the gear component exhibits a relatively
lower strength compared to the other elements. It is advisable to start with the design of the gear.

3.1.4 Design bending stress (σb )

The design bending stress is calculated to ensure that the gear teeth can withstand the bending loads
they will experience during operation. It is a critical factor in gear design to prevent tooth failure.

1.4𝑘𝑙
σb = × σ1
𝜇𝑘σ
Assumptions;
• One directional rotation
• Life factor 𝑘𝑙 = 1
• Safety factor 𝜇 = 2
• No case hardened. Therefore, fillet stress concentration 𝑘𝑙 = 1
1.4 × 1
σb = × 176.75MPa
2×1

σb = 123.73 MPa

3.1.5 Module determination (m)

Module (m) refers to the size of a gear tooth. It is a crucial parameter as it determines the size and
geometry of the gear teeth.

Take for helical gear,

𝜑 = 14°

3 [𝑀𝑡 ]
𝑚 ≥ 1.15 × cos (𝛽) √
𝑌𝑣𝑔 × σbg × φ × 𝑧𝑔

[𝑀𝑡 ] = 𝑀𝑡 × 𝑘𝑑 × 𝑘

𝑃 × 60
𝑀𝑡 =
2𝜋𝑁
𝑃 = 2000𝑊 × 1.2
𝑃 = 2400𝑊
2400 × 60
𝑀𝑡 =
2𝜋 × 150
 𝑀𝑡 = 152.79𝑁𝑚
For the unsymmetric and overhang,
𝑘𝑑 × 𝑘 = 1.5
Therefore,
[𝑀𝑡 ] = 152.79𝑁𝑚 × 1.5
[𝑀𝑡 ] = 229.18𝑁𝑚

3 229.18𝑁𝑚
𝑚 ≥ 1.15 × 𝑐𝑜𝑠(16) √
0.44 × 123.73 MPa × 14 × 64

𝑚 =1.61mm
For optimum design, select a standard module.
Therefore,
𝑚 = 2𝑚𝑚
For the pinion;
(https://www.jetir.org/papers/JETIRFP06022.pdf pg. 7)
𝑘𝑊
𝑀𝑡 = 97420 ×
𝑁2
2.4
𝑀𝑡 = 97420 ×
561.50
𝑀𝑡 = 416.40𝑁𝑚
For a symmetric system
, 𝑘𝑑 × 𝑘 = 1.3
[𝑀𝑡 ] = 416.40𝑁𝑚 × 1.3
[𝑀𝑡 ] = 541.32𝑁𝑚

3 541.32𝑁𝑚
𝑚 ≥ 1.15 × 𝑐𝑜𝑠(16) √
0.44 × 123.73 MPa × 14 × 64

𝑚 = 2.47𝑚𝑚
For optimum design, select a standard module,
𝑚 = 2.5𝑚𝑚

3.1.5 Surface strength (σc ) check

σc = 𝐶𝑟 × 𝐻𝑅𝐶 × 𝑘𝑐1
Where;
HRC = 70
60𝑚𝑖𝑛 1950ℎ𝑟𝑠
𝑁𝑐 = 2100𝑟𝑝𝑚 ( )( ) 10𝑦𝑟𝑠(1𝑠ℎ𝑖𝑓𝑡) = 2.457 × 109 𝑐𝑦𝑐𝑙𝑒𝑠
ℎ𝑟 𝑦𝑟

𝑘𝑐1 = 1.3558𝑁𝑐 −0.0178

𝑘𝑐1 = 1.3558(2.457 × 109 )−0.0178

𝑘𝑐1 = 0.92
Taking

𝐶𝑟 = 2.75
σc = 2.75 × 70 × 0.92

σc = 177.10𝑀𝑃𝑎

• 𝐶𝑟 is a material constant related to the material's hardness and wear resistance.

• HRC is the Rockwell C hardness of the material.
• 𝑘𝑐1 is a factor related to the application and operating condition.

Induced stress

𝑉𝑅 + 1 𝑉𝑅 + 1
σ𝑖𝑛𝑑𝑢𝑐𝑒𝑑 = 0.7 × √ 𝐸[𝑀𝑡 ]
𝑎 𝑉𝑅 × 𝑏

𝑚
𝑎= (𝑧 + 𝑧2 )
2𝑐𝑜𝑠𝛽 1
2.5
𝑎= (17 + 64)
2cos (16)
𝑎 = 105.33𝑚𝑚
𝑏 = 14𝑚
𝑏 = 14 × 2.5
𝑏 = 35𝑚𝑚

3.74 + 1 3.74 + 1
σ𝑖𝑛𝑑𝑢𝑐𝑒𝑑 = 0.7 × √ × 200000[416.40𝑁𝑚]
105.33 3.74 × 35

σ𝑖𝑛𝑑𝑢𝑐𝑒𝑑 = 1.73MPa

σ𝑖𝑛𝑑𝑢𝑐𝑒𝑑 < σc
Therefore, the design is safe.

3.1.6 𝐹𝑤 , 𝐹𝑠 , and 𝐹𝑑
𝐹𝑑 = 𝐹𝑡 × 𝐶𝑣
75
𝐹𝑡 = ℎ𝑜𝑟𝑠𝑒 𝑝𝑜𝑤𝑒𝑟 ×
𝑉𝑚
𝜋𝑑𝑔 × 𝑁4
𝑉𝑚 =
60
𝜋 × 𝑚 × 𝑧4 × 𝑁4
=
60𝑐𝑜𝑠𝛽
𝜋 × 0.0025 × 64 × 150
=
60cos (16)

= 1.31
Barth velocity ratio,
3 + 𝑉𝑚
𝐶𝑣 =
3
3 + 1.31
=
3
= 1.437
2000 75
𝐹𝑡 = ×
746 1.31
𝐹𝑡 = 153.49𝑁

𝐹𝑑 = 153.49 × 1.437

𝐹𝑑 = 220.57𝑁

𝐹𝑠 = σb × 𝑏 × 𝑌𝑣 × 𝑚
𝐹𝑠 = 123.73 × 35 × 0.44 × 2.55
𝐹𝑠 = 4858.88𝑁
𝐹𝑠 > 𝐹𝑑
Design is safe.

Checking 𝐹𝑤
𝑏𝑑𝑄𝑘
𝐹𝑤 =
𝑐𝑜𝑠 2 𝛽
2𝑉𝑅 2 × 3.74
𝑄= = = 1.578
𝑉𝑅 + 1 3.74 + 1
 𝑚𝑧2 2.5 × 64
𝑑= = = 166.44𝑚𝑚
𝑐𝑜𝑠𝛽 cos (16)
(σc )2 × 𝑠𝑖𝑛 ∝ 1 1
𝑘= ×( + )
1.4 𝐸 𝐸
(177.10)2 × sin (20) 2
𝑘= ×( )
1.4 200000
𝑘 = 0.0766𝑁/𝑚𝑚2
35 × 166.44 × 1.578 × 0.0766
𝐹𝑤 =
𝑐𝑜𝑠 2 (16)
𝐹𝑤 = 762.04𝑁
Since,

𝐹𝑤 > 𝐹𝑑
Therefore, the design is safe.
Table 1 Design parameters
Parameters Pinion Gear
Helix angle 𝛽 = 16° 𝛽 = 16°
Pressure angle 𝛼 = 20° 𝛼 = 20°
module 𝑚 = 2.5𝑚𝑚 𝑚 = 2.5𝑚𝑚
PCD 𝑑𝑝 = 44.21𝑚𝑚 𝑑𝑔 = 166.44𝑚𝑚
Face width 𝑏 = 35𝑚𝑚 𝑏 = 35𝑚𝑚
Tip diameter 𝑑𝑎1 = 54.71𝑚𝑚 𝑑𝑎2 = 176.44𝑚𝑚
Root diameter 𝑑𝑓1 = 32.21𝑚𝑚 𝑑𝑓1 = 154.54𝑚𝑚
Centre distance 𝑎 = 105.33𝑚𝑚
Material 303 stainless steel 304 stainless steel

3.2 Shaft Selection

In this gearbox design, the primary focus lies on three integral shafts: the input shaft, counter-shaft,
and output shaft. These components hold pivotal roles in ensuring the gearbox operates seamlessly
and effectively.
Beginning with the input shaft, it serves as the entry point for mechanical power from an external
source into the gearbox. Essentially, it kick-starts the entire gear train. Ensuring this shaft is robust
enough to handle the initial power input and transfer it efficiently through the gear system is of
paramount importance.
counter-shaft is a crucial intermediary in the process of attaining the intended reduction in speed.
The function of this shaft is to receive power from the input shaft and afterwards convey it to the
output shaft. Consider it as the intermediary component within the gearbox mechanism, enabling the
seamless transmission of power.
Ultimately, the output shaft serves as the ultimate recipient of the final mechanical output. This
component signifies the final stage within the gear train system, wherein the generated power is
afterwards utilized for its designated purpose. The optimal construction of this shaft is of utmost
importance in order to facilitate the efficient transmission of power with minimal loss.
The design process for each of these shafts involves a thorough evaluation of various factors,
including careful selection of appropriate materials and the calculation of optimal diameters. A
rigorous process is applied to guarantee the durability of the shafts, allowing them to endure a wide
range of stresses and strains faced over their operational lifespan. Considerable importance is also
attributed to the incorporation of bearings along the shafts. Bearings serve a critical role in the
reduction of friction and provision of important support, hence facilitating the smooth rotation of
shafts.
Furthermore, it is important to acknowledge that there is significant emphasis placed on the careful
alignment of gears. The shafts play a critical part in ensuring accurate alignment of all gears, which is
essential for obtaining optimal performance defined by seamless operation and efficiency.
Maintenance and lubrication requirements; Regular inspections and proper lubrication are recognized
as critical practices for ensuring the longevity and reliability of these shafts. This approach ensures
that the design is not solely focused on performance but also durability over the gearbox's service life.
In essence, the design approach is all-encompassing, taking into account the pivotal role that each of
these shafts plays in the gearbox's operation, from the intake of power to its final utilization. Each
shaft is crafted with precision and care to guarantee optimal performance and longevity.

Figure 2 Transmission shaft

I. Material selected
AISI 1050 Carbon Steel
Table 2 Shafts speed

Item Speed(rpm)
Input shaft 2100
 counter-shaft 561.50
Output shaft 150

Figure 3 Two-stage speed reduction configuration

II. The torque on the shaft from the power

𝑃(𝑘𝑊)
𝑇(𝑁𝑚) = 9548 ×
𝑟𝑝𝑚
2.4
𝑇(𝑁𝑚) = 9548 ×
2100
𝑇 = 10.912𝑁𝑚
Note: Design power is the one used to calculate the torque.
III. Torsional stress
16𝑇
𝜏𝑠 =
𝜋𝐷 3
For shafts with allowance for keyways, it is reasonable to consider the maximum permitted shear
stress as 42 MPa.
Therefore,
16 × 10.912
42𝑀𝑃𝑎 =
𝜋𝐷 3
For the input shaft,
𝐷 = 10.98𝑚𝑚
This diameter is below the standard recommended shaft diameter. Therefore, guided y standard shaft
diameter, 25mm diameter, is selected for the input shaft.
The concept of the equivalent bending moment can be described as the moment that, when applied
independently, generates the same level of tensile or compressive stress as the real bending moment.
Restricting the maximum normal stress, namely setting it equal to the permitted bending stress.
From gear design;
𝑀𝑡 = 541.32𝑁𝑚
And
σb = 123.73 MPa
Therefore,
𝜋
𝑀𝑡 = × σb × 𝑑 3
32
𝜋
541.32𝑁𝑚 = × 123.73 MPa × 𝑑3
32
For the gear shaft,
𝑑 = 35.45𝑚𝑚
Guided by the standard shafts’ dimensions, a 40mm shaft diameter for the output shaft is selected.
The commonly accepted dimensions for transmission shafts are as follows: shafts range from 25 mm
to 60 mm in increments of 5 mm and from 60 mm to 110 mm in increments of 10 mm.
IV. Shaft endurance limit
𝑆𝑒 = 0.55𝑆𝑢𝑡
𝑆𝑒 = 0.55 × 690𝑀𝑃𝑎
𝑆𝑒 = 379.50𝑀𝑃𝑎

3.2 Bearing selection

The selection of a ball bearing for the gearbox is based on several key considerations that make it a
suitable choice:
• High-Speed Efficiency
Ball bearings are renowned for their adeptness at managing high speeds. It is paramount in the
gearbox, where rapid rotations are vital. The utilization of ball bearings guarantees a smooth and
efficient system, sidestepping issues linked to excessive friction or heat buildup.
• Adequate Load Handling
Ball bearings excel in applications with moderate to light radial loads. Given the gearbox's primary
focus on power transmission and speed reduction, the loads placed on the bearings fall well within
the range that ball bearings can capably manage.
• Minimized Friction
With low starting and running friction, ball bearings enhance the gearbox's efficiency in power
transmission. It aligns seamlessly with the aim of curbing energy loss in the gearbox, ensuring that a
substantial portion of the input power is effectively conveyed to the output.
• Streamlined Design
Ball bearings are typically more compact and lightweight compared to alternative bearing types. It
proves advantageous in gearbox design, allowing for a more condensed and efficient configuration. It
not only conserves space but also trims down the overall weight of the system.
• Economical Choice
 Ball bearings generally come at a more budget-friendly price compared to some other bearing
varieties. This consideration is pivotal in upholding the economic viability of the gearbox, all the while
preserving performance and dependability.
• Low Maintenance Demands
Ball bearings demand relatively minimal upkeep in comparison to other bearing types. It translates to
extended operational periods for the gearbox, with infrequent requirements for servicing or bearing
replacement. It substantially contributes to an extended operational lifespan.
• Wide Availability
Ball bearings enjoy extensive usage across various industrial applications and are readily accessible
from a diverse array of suppliers. It ensures that replacement components can be effortlessly procured
should maintenance or repair needs arise.
• Well-suited for Uniform Load Distribution
Ball bearings excel in uniformly loaded applications, harmonizing with the intended use of the
gearbox. They evenly distribute the load across the rolling elements, guaranteeing that each bearing
can capably manage its portion of the load.

Figure 4 ball-bearing

Expected life of the ball-bearing

Running 7.5 hours a day for 5 days a week for 10 years.
The number of revolutions the ball bearing will be expected to make in a lifetime.
= 7.5 × 60𝑚𝑖𝑛 × 5𝑑𝑎𝑦𝑠 × 52𝑤𝑒𝑒𝑘𝑠 × 10𝑦𝑟𝑠 × 2100𝑟𝑝𝑚
For the input shaft
= 2.457 × 109 𝑟𝑒𝑣𝑠
For the counter-shaft
= 6.570 × 108 𝑟𝑒𝑣𝑠

For the output shaft

= 1.755 × 108 𝑟𝑒𝑣𝑠
For a failure rate of 2%, 𝐾𝑅 = 0.33 from the reliability factor table.
Using the formula,
𝐶
𝐿𝑝 = 𝐾𝑅 ( )3
𝑃
For a 25mm diameter reading, the value of 𝐶 = 16.9𝑘𝑁 from the load chart.
For 40mm diameter 𝐶 = 33.7𝑘𝑁
For the input shaft,
16.9𝑘𝑁 3
2.457 × 109 𝑟𝑒𝑣𝑠 = 0.21( )
𝑃
𝑃 = 7.4𝑁
For the counter-shaft,
When 𝑑 = 25𝑚𝑚
16.9𝑘𝑁 3
6.570 × 108 𝑟𝑒𝑣𝑠 = 0.21( )
𝑃
𝑃 = 11.6𝑁
When 𝑑 = 40𝑚𝑚
33.7𝑘𝑁 3
6.570 × 108 𝑟𝑒𝑣𝑠 = 0.21( )
𝑃
𝑃 = 23.0𝑁
For the output shaft,
33.7𝑘𝑁 3
1.755 × 108 𝑟𝑒𝑣𝑠 = 0.21( )
𝑃
𝑃 = 35.8𝑁
Material selected
Case-hardened AISI 3310
Bearing properties
Table 3 Bearing properties

Bearings Bearing Bore C Outer Width Fillet

number diameter (kN) diameter(mm) (mm) radius
(mm)
1 6305 25 16.9 62 17 1.016
2 6308 40 33.7 90 23 1.524

3.3 Shafts keys

Rectangular keys will play a crucial role in securely connecting the rotating gears to their respective
shafts. These keys will ensure that torque is efficiently transmitted from the shaft to the components,
enabling effective power transfer within the gearbox. Typically, a rectangular key is employed for shaft
diameters ranging from 25 mm to 500mm.

Figure 5 Shaft keyway and key

Material selected

20MnCr5 Steel

Standard sizes have been considered;

Table 4 Key dimensions

Diameter Width Depth Shaft keyway Hub keyway

(mm) (mm) (mm) depth (mm) depth (mm)
25 8 7 4 3.3
40 12 8 5 3.3

3.4 Tolerances
Interference fit is used to fit the bearing to the shaft. An interference fit means that the bearing's inner
race is slightly larger than the diameter of the shaft. It requires the bearing to be pressed onto the
shaft, creating a tight and secure connection.
Table 5 Tolerance limit

Item Tolerances
(mm)
Shaft ±0.05
Bearing ±0.05
Gears ±0.05
Key ±0.02
Keyway ±0.02
Permissible surface roughness R, (pm)= 4

3.5 Mounting Bolts

The gearbox is designed with specific mounting points or flanges on its housing. These are reinforced
areas that are structurally capable of bearing the weight and forces exerted during operation.

M8 x 30mm bolts will be used for mounting.

3.6 Gearbox Housing

By opting for the Aluminum 6061 Alloy for the gearbox housing, a robust component with exceptional
tensile strength and superior machining capabilities is achieved. This choice exemplifies the company’s
commitment to crafting a durable and efficient gearbox, aligning seamlessly with industry standards
and best practices.

4. Conclusion
This gearbox design project represents a culmination of meticulous engineering efforts aimed at
meeting stringent customer requirements. The primary goal was to create a gearbox capable of
delivering 2 kW of power at a steady-state input speed of 2100 rpm while maintaining a precise output
speed of 150 ± 1 rpm. With a targeted operational lifespan of 10 years, accounting for 7.5 hours per
day, 5 days per week, and a maximum allowable failure rate of 2%, the design process was carried out
with utmost precision.
With a solid grasp of compound gear train fundamentals, the project progressed through iterative
stages, focusing on critical aspects like power considerations, gear selection, shaft layout, and material
choices. Helical gears emerged as the preferred choice due to their smooth operation and noise-
reduction capabilities. Calculations for power and speed requirements were carefully caried out, with
specific aim of achieving the specified velocity ratio.
A comprehensive analysis and specification of the various shafts, covering the input shaft, counter-
shaft, and output shafts, was conducted. Every individual component was subjected to a
comprehensive analysis, conducted with the highest level of precision, taking into account many
variables such as the choice of materials, diameter, and strength. The choice of ball bearings was
determined by their ability to perform effectively at high speeds, their advantageous characteristics
of low friction, and their cost-effectiveness, making them well-suited for meeting operational
requirements.
The implementation of rectangular keys was employed with the objective of improving the secure and
efficient transfer of power between shafts and gears. The implementation of accurate tolerances was
carried out with careful attention to detail in order to ensure a precise and secure alignment, hence
minimizing the probability of problems such as excessive looseness or interference.
Furthermore, the gearbox incorporates a mounting design that employs four robust bolts, therefore
guaranteeing the system's stability and structural integrity during its operational phase. The
mentioned mounting approach provides a dependable method of attachment that exhibits the ability
to withstand the dynamic forces frequently encountered in industrial environments.
The gearbox's design serves as a prime example of a systematic and comprehensive engineering
approach, effectively incorporating theoretical principles alongside practical considerations. The
resulting solution is designed to meet client requirements in a manner that exceeds expectations,
offering reliable and efficient performance during its intended lifespan of 10 years. This project
exemplifies the company's unwavering commitment to precise engineering and innovative design,
setting a new standard for the outstanding performance of gearboxes in industrial environments.

5. References
1) Vilmos Simon. 2017. Optimization of Gear Design and Manufacture.
https://www.researchgate.net/publication/316816552_Optimization_of_Gear_Design_and_
Manufacture
2) Salawu, Ajayi and Inegbenebor. 2020. Material Selection and Processing Techniques: Crucial
Factors Engineering for Gear
https://eprints.covenantuniversity.edu.ng/15767/1/Salawu_2021_IOP_Conf._Ser.__Mater._
Sci._Eng._1107_012114.pdf
3) H. Delibaş, Ç. Uzay and N. Geren. 2017. Advanced Material Selection Technique For High
Strength and Lightweight Spur Gear Design.
https://www.researchgate.net/publication/321782148_Advanced_Material_Selection_Tech
nique_For_High_Strength_and_Lightweight_Spur_Gear_Design
 4) Jing LI and Jing Huang. 2016. Transmission Efficiency Analysis and Experiment Research of
Gear Box. file:///C:/Users/Admin/Downloads/25871472.pdf.
5) Habermehl, Christian, and Georg Jacobs. 2020. A modeling method for gear transmission
efficiency in transient operating conditions.
https://www.sciencedirect.com/science/article/abs/pii/S0094114X20302172
6) Kapil Gupta. 2018. Recent Developments in Additive Manufacturing of Gears: A Review.
https://www.researchgate.net/publication/327475076_Recent_Developments_in_Additive_
Manufacturing_of_Gears_A_Review.
7) Li, C.H. and H.S. Chiou. Integration of finite element analysis and optimum design on gear
systems.
https://www.researchgate.net/publication/245053385_Integration_of_finite_element_anal
ysis_and_optimum_design_on_gear_systems.
8) Clancy, Ryan. 2023. Tips to extend the lifetime of an industrial gearbox.
https://insights.globalspec.com/article/20005/tips-to-extend-the-lifetime-of-an-industrial-
gearbox.
9) Nguyen, C.D. and A. Prosvirin. 2022. A Reliable Fault Diagnosis Method for a Gearbox System
with Varying Rotational Speeds. https://www.mdpi.com/1424-8220/20/11/3105.
10) Serpil Karakuş.2023. DESIGN AND MANUFACTURING OF A TWO-STAGE
11) REDUCTION GEARBOX WITH 3D PRINTERS. https://dergipark.org.tr/tr/download/article-
file/2781091
12) Robert Norton. Machine design.
https://mmsallaboutmetallurgy.com/wp-content/uploads/2019/02/machine-design.pdf.pdf

6. Appendices
6.1 304 stainless steel
6.2 303 Stainless steel

6.3 Gear module

6.4 Endurance limit for shafts
6.5 Material used for shafts

6.6 Ball-bearing reliability data-sheet

6.7 Ball-Bearing Load Chart

6.8 Case-hardened AISI 3310

6.9 Standard sizes for shaft keys

6.10 Material selected for shaft key