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Speed Reducer Design

INTRODUCTION
In an industry, the machineries involved oftentimes do not employ direct drives. They
subsequently undergo trains of mechanism. Parts of these mechanisms are speed manipulations. It is for
the reasons that the drives involve do not match the speed-torque combinations, or that the
combinations present needs further alterations or switching among different operating parameters are
desired.
The job of altering speeds of drives is well done by gearboxes. They are mechanisms which are
simple in principle but needs accuracy in design. This will ensure smooth operations, with its high
efficiency and highly-optimized parameters.
This paper involves the design of a gearbox, particularly a speed reducer. The velocity ratio is
4:1, with its output speed being a quarter of its input speed of 3000 rpm. The mechanism is to transmit a
350 kW power at a higher torque. A particular application of this is in turbine drives. The re is only a
single speed reduction, meaning there is only a pair of gears involved. The gears used are spur gears.
The teeth profile is of the commonly used 14.5 full-depth involute system. Though helical gears provide
smoother operation, and the doubled configuration eliminates axial thrust of the former, spur gears are
chosen due to its simplicity.

Speed Reducer Design

GEAR DESIGN

Initial Parameters
Power Transmitted P: 350 kW
Input Shaft Speed N 1:

3000 rpm

Gear Ratio G:

4:1

Calculations
Angular Speed of the Input Shaft
(

)(

Torque for the Input Shaft

Gear Type Selection

For the operating parameters involved, a spur gear is contemplated. The teeth profile will be
that of a 14.5 Full-Depth Involute System. The material for the pinion and the gear is the same alloy
steel, case hardened, with a modulus of elasticity set at 200 Gpa.

Gear Calculations
Since the pinion and gear are of the same material, the pinion is the weaker of the two. Thus,
strength calculations will be based on the pinion.

Speed Reducer Design

Minimum Number of Teeth of Pinion to Avoid Interference

From the proportions of 14.5 spur gears,

Tangential Load

For light shocks, and 8-10 hours per day use,

Speed Reducer Design

Lewis Form Factor (Tooth Form Factor)

For 14.5 Full-Depth Involute System,

Peripheral Velocity

Tangential Load (Other Form)

For alloy steel, case hardened,

Assuming peripheral velocity to be within 10 m/s to 20 m/s,

Face width for cut teeth ranges from 9.5m to 12.5m,

Speed Reducer Design

Peripheral Velocity Check

Face Width

Tangential Load

Dynamic Load

Speed Reducer Design

Since the pinion and gear are of the same material,

For 14.5 Full-Depth Involute System,

For carefully-cut gears and m=8mm,

Static Load

Wear Load

Speed Reducer Design

For external gears,

Thus, changes must be made to increase the wear strength of the tooth. For this, the number of teeth is
raised to 32.

After carrying out the same procedure as above, the new values are the following.
Module number

8 mm

Tooth form factor

0.103

Velocity factor

0.2717

Peripheral velocity

40.21 m/s

Speed Reducer Design

Face width

100 mm

Pitch diameter

256 mm

Tangential load

10878.73 N

Tooth error action

0.0386 mm

Dynamic factor

413.02 N/mm

Dynamic load

48240.05 N (Service factor is neglected)

Static load

144437.86 N

Wear load

49979.47 N

Gear Proportions

Speed Reducer Design

SHAFT DESIGN

Normal Load

Weight of Pinion (approximate)

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Speed Reducer Design

Resultant Load
( )

Length of Shaft

Bending Moment Due to Normal Load

Pinion Shaft Diameter

Using 40C8 Steel,

1

Distance between the centers of the gear and the bearing

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Speed Reducer Design

Shaft Check
Deflection at Gear Point

Slope at Bearing Point

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Speed Reducer Design

Gear Shaft Diameter

Gear shaft diameter could be approximated by

Gear Construction
Pinion
Dimension Check

Since the hub length is less than the face width, the hub length will be set equal to the face width.

For the arms, since DG= 256 mm, the gear should be provided with n=4 arms.
The arms are assumed to be elliptical in cross section, which tapers towards the rim. Furthermore, it is
assumed that the minor axis is half the major axis.

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Speed Reducer Design

The arms are designed for the stalling load.

Setting bending stress equal to allowable static stress,

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Speed Reducer Design

For the rim,

For the keyway

Gear

For the arms, since DG= 1024 mm, the gear should be provided with n=6 arms.
The arms are assumed to be elliptical in cross section, which tapers towards the rim. Furthermore, it is
assumed that the minor axis is half the major axis.

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Speed Reducer Design

(
(

)
)

For the rim,

For the keyway

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Speed Reducer Design

BEARING SELECTION

Life of Bearing
For machines working 8 hours per day and not always fully utilized e.g. stationary electric motors,
general purpose gear units,

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Speed Reducer Design

Radial Load

Speed

Dynamic Equivalent Radial Load

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Speed Reducer Design

For light shock loads,

Basic Dynamic Load Rating for Pinion Shaft Bearing

(

For ball bearings,

For a pinion shaft diameter of 55 mm, a ball bearing with a 50 mm bore is selected.

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Speed Reducer Design

Bearing Selected
Manufacturer:

TIMKEN

Series:

Medium 5300 Series

Bearing No.:

5310W

Bore:

50 0.012 mm

Outside Diameter:

110 0.015 mm

Width:

44.45 2 mm

Static Load Rating:

97000 N

Extended Dynamic Load Rating: 126000 N

Basic Dynamic Load Rating for Gear Shaft Bearing

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Speed Reducer Design

For a gear shaft diameter of 90 mm, a ball bearing with a 85 mm bore is selected.

Bearing Selected
Manufacturer:

TIMKEN

Series:

Light 200K Series

Bearing No.:

217K

Bore:

85 0.02 mm

Outside Diameter:

150 0.018 mm

Width:

28 0.2 mm

Static Load Rating:

62200 N

Extended Dynamic Load Rating: 95900 N

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Speed Reducer Design

GEARBOX DIMENSIONS

Largest Dimension

Dimensions
For case-hardened gears,

Bolt Selected (from METTLER TOLEDO Weigh Module Systems Handbook)

Nominal Thread Size:

M16

Thread Pitch:

2 mm

Nominal Diameter:

16 mm

W:

24 mm

H:

10.18 mm

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Speed Reducer Design

[
Bolt Selected
Nominal Thread Size:

M24

Thread Pitch:

3 mm

Nominal Diameter:

24 mm

W:

36 mm

H:

15.215 mm

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Speed Reducer Design

For pinion shaft bearing,

For gear shaft bearing,

Each bearing housing is bolted with six M10 bolts.

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Speed Reducer Design

Bolt Selected
Nominal Thread Size:

M10

Thread Pitch:

1.5 mm

Nominal Diameter:

10 mm

W:

17 mm

H:

7.18 mm

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Speed Reducer Design

IMAGES

Figure 1

Figure 2

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Speed Reducer Design

Figure 3

Figure 4

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Speed Reducer Design

Figure 5

Figure 6

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Speed Reducer Design

Figure 7

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Speed Reducer Design

Figure 8

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Speed Reducer Design

Figure 9

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Speed Reducer Design

REFERENCES

A Textbook of Machine Design

RS Khurmi, JK Gupta
Machine Design II, Module 2-Gears, Lecture 17-Design of Gearbox
K Gupinath, MM Mayuram
TIMKEN Ball Bearings Catalog
Bolt Dimensions
METTLER TOLEDO Weigh Module Systems Handbook