Gearbox Design

Gearbox Design Issues:

1. Shafts
2. Rotating Elements
(i.e., gears, sprockets, pulleys, etc.)
3. Bearings
4. Securing elements
5. Seals
6. Housing layout
 Shafts: Functions

•Locate and secure components in

an appropriate manner and in their
proper position.
•Transmit all applied forces to their respective
reaction point in the most efficient way.
Shaft Components To Consider
Shaft Components To Consider
Internal Components, such as, gears.
Shaft Components To Consider
Output Devices: Pulleys, Sprockets, Sheaves, etc.
 Shaft Components To Consider
Bearings: ball, roller, sliding.
 Methods of Securing Components
1. Welding
Permanent assemblies
2. Machining from the solid shaft Not intended for
3. Interference or transitional fits replacement
4. Locating pins or dowels pins
5. Spacers and Sleeves
6. Keyways and keys
7. Splined Shafts
8. Steps and shoulders
9. Threaded fasteners
10. Clamping rings, collars, end caps
11. Friction fits (Taper Lock)
Secure the Components Circumferentially
Splines
External splines

Internal splines
Secure the Components Circumferentially
Keys, pins, set screws, etc.

Pin hole in the shaft

Key

Pin
Pin hole in the hub
Secure bearing Circumferentially
by press-fit Inner ring press fit to the shaft

Outer ring press fit to the housing

Secure the Components Axially by
Shoulders, Snap rings (or retaining rings)

Secured by the snap rings

Secure the Components Axially by
Nuts
Bearing Lock Nut:
Couplings

Flexible couplings allow

axial, radial, and angular
Misalignments, which are
easy to assembly and disassembly,
As well as maintenance

A fluid coupling or hydraulic

coupling is a hydrodynamic
or 'hydrokinetic' device
used to transmit rotating
mechanical power.

For more information, please visit: www.ktr.com

Couplings
​ specially within tough applications, drive
E
components and processing machines are
subject to extreme loads. FLUDEX®
couplings limit start and maximum torque
within the drive train and serve as starting
aids for the motor and as overload
protection in the case of an incident

For more information, please visit: www.ktr.com

Couplings
Gear couplings basically belong to
the category of flexible couplings
which are capable of transmitting
very high torques

For more information, please visit: www.ktr.com

Couplings
Roller chain coupling is a mechanical device
composed of a double-strand roller chain and
two modified sprockets. The design is simple
and highly effective, despite its small size, and
is composed of a robust chain and specially cut,
hardened-tooth sprockets that allow a high
amount of torque to be transmitted.

For more information, please visit: www.ktr.com

Couplings

ROTEX® torsionally flexible jaw

couplings are elastomer
couplings characterized by a compact design.

For more information, please visit: www.ktr.com

Couplings

Grid couplings are multi-piece mechanical shaft

couplings used to transmit torque and rotation
between shafts in mechanical power transmission
assemblies. The grid element or spring is made of
high tensile alloy steel. The grid element transmits
torque and accommodates some misalignment and
shock loading in the system.

For more information, please visit: www.ktr.com

Seals: Labyrinthseals, O-rings, lips,
A labyrinth seal is a type of
mechanical seal that provides
a tortuous path to help
prevent leakage
Gearbox forces to be considered
1. Tangential Drive Force on Gear Teeth, Ft
(torque transmitted to do work)
Ft
Torsion on shaft.

F
Fa

Fr
 Gearbox forces to be considered
2. Axial Force Due to Helix Angle, Fr
(not to do work)
-Axial tension/compression on shaft.
-Cyclical bending moment on shaft.
F t

Fa
Fr
 Gearbox forces to be considered
3. Radial Force on Gear Tooth, Fr
(not do work)
-Cyclical bending force on shaft.

F t

Fa
Fr
Gearbox forces to be considered
4. Weight of the Gear and Shaft

-Radial Bearing reactions.

Gearbox forces to be considered
5. Externally Applied Loads

-Overhung bending moment

-Axial Thrust Load on the shaft.

Overhung Bending
due to belt or chain
tension

Axial Thrust
Detailed Shaft Design Features
• Keyways
• Steps & Shoulders
• Fillets and Chamfers
• Notches and Grooves
• Thread Details
• Bearing Seats and Housings
• Gear Mounting Techniques
• Spacers and Sleeves
Common practice in Shaft Design
• Shafts get larger as speeds are reduced
• Small pinions are often machined onto shafts
• Larger gears generally use keys to transmit torque to shafts
• Steps, Spacers and Retaining Rings are common ways to locate
gears
• Use Shims for adjustment and fine alignment of parts
• Bearing Locking Nuts are a good way to secure Bearings
• Consider stress risers due to grooves and sharp steps in shafts
• Use chamfers to ease assembly and avoid interferences