ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology

I
Vol-03, Issue-06, June 2015

Adaptive Design of Machine Tool Gearboxes

Dr M. A. Asy
mohamedasy2010@yahoo.com
Department of Production Engineering & Mech. Design
University of Menoufia
Shebin El-Kom, Menoufia, Egypt

Abstract
This paper aims to design multi speed minimum size gearboxes.
Simplification in gear meshing location and double speed electric
motors are proposed to achieve this goal. Simplified gear meshing
location is the use of one or more driven gears on the intermediate
shaft as driver gears for the last shaft. Keeping the machine tool
gearbox speeds in geometrical progression is the most important
constrain. Two case studies are considered; four and
six speeds gearboxes with three shafts. A comparative study for
the two gearboxes is made in case of conventional structure and
two simplified meshing locations. The minimum number of teeth
and the actual speeds are calculated according to the speed chart
construction, considering one of the standard progression ratios
and compared with the theoretical speeds. The obtained actual
speeds are in a geometric progression and the deviation between
theoretical and actual speeds are in the permissible limits. Saving
ratio in gears and gear utilization factor in 4, 6, 8, and 9 speed
gearboxes are calculated. Reducing the number of gears in
gearbox with two simplified meshing positions has positive effect
on the gearbox dimensions and consequently reducing the overall
cost. The maximization of gear utilization factor is made by
driving these gearboxes with double speed electric motors
which doubles the number of speeds produced when using single
speed electric motors are used.

1. Introduction:
In designing gear drives, reliability of operation, efficiency,
service life, load carrying capacity and overall cost are
considered. Efficiency of gear drives significantly depends on
the frictional losses during the operation especially in low
efficiency gear drives. Overall cost includes manufacturing,
running and maintenance. Gears have many advantages that
makes them vital power transmitting elements in any
mechanical system. The primary objective of the application
of gear drive is to transmit the power between mating gears
at constant velocity ratio, which is essential in machine tools.
Designers of multipurpose machine tools had to provide a
certain speed range which covers the requirements of different
operations, types and shapes of work pieces and qualities of the
surfaces that are to be machined. Values of the required cutting
speeds depend upon technical and economic considerations.
Greater variety of materials used for tools and work piece, the
wider speed range is required for the cutting speed range.
Several references enhanced the design of gears and/or gear

690

boxes [1-13]. Structural formulae, structural diagrams, and ray

diagrams i.e. speed charts were constructed and a design
procedure is carried out in details for 4 and 6 speed gearboxes.
The number of teeth for all gears, deviation between
theoretical and actual speeds is estimated as given in
references [7& 13]. From the previous studies, it is clear that
there is a shortage of the published material in the field of
machine tool multi-speed gearboxes design. Very limited
attention was paid on those which have simplified meshing
locations and driven by single and/or double speed electric
motors. In this paper, two stages (three shafts) four and six
speed gearboxes driven by double speed electric motor are
considered. A comparative study for the two gearboxes is made
in the case of conventional structure and two simplified
meshing locations. The minimum number of teeth and the
actual speeds under specified standard progression ratios are
calculated based on the speed chart. The actual speeds are
compared with the theoretical speeds. The obtained actual
speeds are in a geometric progression. The deviation between
theoretical and actual speeds are in the permissible limits.
Saving ratio in gears and gear utilization factor in 4, 6, 8, and 9
speed gearboxes were calculated. Reducing the number of gears
in gearbox with two simplified meshing positions has positive
effect on the gearbox dimensions and consequently reducing
the overall cost. The maximization of gear utilization factor is
achieved by using double speed electric motors. Actually,
double speed motors add two speed, one stage reduction.
2. Design Procedure:
Design of gearboxes with two simplified meshing locations
involves two case studies; four and six speeds. The procedure
contains the construction of a kinematic diagram, number of
teeth calculations, calculations of actual speeds, and error
between actual and theoretical speeds. Moreover, error between
actual and theoretical speeds are compared with the permissible
error limits.
Case (1):
Four Speed Gearbox
The kinematic diagram of conventional gearbox delivers 4
speeds has the structural diagram shown in Fig. (1-a).

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

b is the distance between the second and third shafts in the

gearbox.
a= (mZ3/2+ mZ4/2) = (mZ4/2)* (Z3/Z4 +1) = (mZ4/2)/ (i2+1)
(5)
b= (mZ5/2+ mZ6/2) = (mZ5/2)* (1+Z6/Z5)= (mZ5/2)/ (1+1/i3)
(6)
a/b = (i2+ 1)/(1+1/i3) = (i2i3+i3)/(i3+1)
(7)

Also,
a= (mZ1/2 + mZ2/2) = (mZ2/2)/ (i1+1)
b= (mZ7/2 + mZ8/2) = (mZ7/2)/ (1+1/i4)
a/b = (i1+ 1)/ (1+1/i4) = (i1i4+i4)/ (i4+1)

Fig. (1) Kinematic Diagram of 4 Speed Gearboxes:

a- Conventional
b- Two Simplified Meshing locations.

Actual Speed Equations:

N1 = N * Z1/Z2 *Z5/Z6 = N*i1*i3
N2 = N * Z1/Z2 *Z7/Z8 = N*i1*i4
N3 = N * Z3/Z4 *Z5/Z6 = N*i2*i3
(1)
N4 = N * Z3/Z4 *Z7/Z8 = N*i2*i4
Where:
N = the input speed on the first shaft in the gearbox.
N1= highest speed at the gearbox spindle rpm
N4 = lowest speed at the gear box spindle rpm
i1, i2, i3 and i5 = the transmission ratios for Z1/Z2, Z3/Z4, Z5/Z6
and Z7/ Z8 respectively
Assume:
N1/N = io
(2)
i1* i3 = N1/N= io
i1* i4 = N2/N= N1/ (N*f) = io/ f
i2* i3 = N3/N= N1/ (N*f2) = io/ f2
(3)
i2* i4 = N4/N= N1/ (N*f3) = io/ f2
Where:
io = the ratio between the highest speed on the gearbox spindle
to the input speed on the first shaft.
f = the base of progression transmission ratio
From equation (3):
i3/ i4 = f
i1/ i2 = f2
(4)
For the gearbox shown in Fig. (1-a) If two simplified meshing
locations are made the kinematic diagram will be as shown in
Fig. (1-b).
The gearbox in simplified locations form has two gears
working as driven and drivers according the path of power and
the engagement mechanism. Because these two gears working
as idler gears, they have the same specifications i.e. number of
teeth, module and dimensions i.e. Z2 = Z7 and Z5 = Z6. To
achieve this condition a special treatment should be followed
through the following design procedure.
Assume:
a is the distance between the first and second shafts in the
gearbox.

691

(8)
(9)
(10)

From Eqs. (7) and (10)

(i2i3+i3)/ (i3+1) = (i1i4+i4)/ (i4+1)
From equation (3) substitute into equation (4)
(io/f2 +f * i4)/ (f * i4+1) = (io/f + i4)/ (i4+1)
i4(io+ f3 f2io f2) = io(f-1)
i4 = [io* (f-1)/ [(f-1)*{f2 io * (f+1)}]
i4 = io/ [f2 io * (f+1)]
Assume:
A = [f2 io * (f+1)]
i4 = io / A
According to equation (3)
i3 = i4 * f
i3 = io * f/ A
i2 * i3 = io /f
i2 = A/f3
i1 = A/ f

(11)
(12)

(13)
(14)

(15)
(16)

According to Fig. (2)

Z1/ Z8 = Z1/ Z2 * Z7/Z8 = i1 * i4 = io/f
Z3/ Z6 = Z3/ Z4 * Z5/Z6 = i2 * i3 = io /f2
It is clear that the small transmission ratio is io /f2. Therefore, it
must calculate the limits for this value in the case of using the
simplified meshing position gearbox.
Also, the lowest transmission ratio is i2 = A/f3 which must be
1/4
(17)
If the progression ratio is f = 2.0
io/ f = io/4 1/4
(18)
io = 1.0
A = [f2 io * (f+1)] = 1.0
(19)
i2= A/f3 = 1/8
If io > 1 then i2 <1/8
This means io must be less than unity, also Z3/Z6 must be less
than 1/4.
It is clear that the best condition for this case is when i2 =
Z3/Z6;
Z3/Z6 = i2 * i3 = i2
(20)
This means i3 = 1.0

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

i3 = io* f /A = 1.0
(21)
A = io *f
Also, A = [f2 io * (f+1)]
A = [f2 io * (f+1)] = io* f
(22)
f2 = 2*io* f + io
io = f2/ (2*f+1)
(23)
Equation (23) represents the general equation to design the
gearboxes with Simplified meshing locations

For Stage II
(The transmission ratios between the second and third shafts).

Table (1) the Relation between the Suitable Transmission Ratios

and Progression Ratio for Gearboxes Deliver 4 speeds and has
Two Simplified Meshing Locations [8].
symbol

Table (3) Conversion of Transmission Ratio Fraction into Form

of Numerator and Denominator.

Value

1.06

1.12

1.26

1.41

io
A
i1
i2
i3
i4

1.58

0.36

0.39

0.45

0.38
0.36
0.322
1
0.944

0.435
0.39
0.309
1
0.89

0.56
0.442
0.28
1
0.792

0.525

0.6

0.8

0.735
0.52
0.26
1
0.715

0.95
0.595
0.237
1
0.623

1.6
0.8
0.2
1
0.5

CI= 82 teeth
Where CI is the summation of teeth for pair gears between the
first and second shafts.
Z3 = 26*82/126 = 17 teeth
Z4 = 100* 82/126 = 65 teeth
Z1 = 52* 82/152 = 28 teeth
Z2= 100*82/152=54 teeth

ij
ij = Zi/ Zj+1
i3 = Z5/Z6
i4 =Z7/Z8

According to kinematic diagram shown in Fig. (1-b) and Table

(1):
The Design procedure For 4 speed gearbox with two
simplified meshing locations:
Take f= 1.41
io = 0.526
i1= Z1/Z2=0.52
i3= Z3/Z4= 0.26
i3= Z5/Z6= 1
i4= Z7/Z8 = 0.715

ii= fi/ gi
Zi/ Zi+1
1
715/1000

(fi+ gi)
(Zi+ Zi+1)
2
1715

The maximum power involves the minimum size gear

Z5 = Z6 = Z4 = 65 teeth
CII= Z5 + Z6 =130 teeth
Where CII is the summation of teeth for pair gears between the
second and third shafts.
Z7+ Z8 =130 teeth
Z2= Z7 = 54 teeth
Z8 = 130- 54 = 76 teeth
Table (4) Number of Teeth for all Gears.
Gear No.
No. of Teeth

Z1
28

Z2-7
54

Z3
17

Z4-5
65

Z6
65

Z8
76

No. of teeth calculations:

For Stage I (The transmission ratios between the first and
second shafts).
Table (2) Conversion of Transmission Ratio Fraction into Form
of Numerator and Denominator.
ij

ii= fi/ gi

(fi+ gi)

ij = Zi/Zj+1
i1 = Z1/Z2
i2 = Z3/Z4

Zi/Zi+1
52/100
26/100

Zi/Zi+1
152
126

Where:
fi= The number of teeth for the driver gear
gi= The number of teeth for the driven gear
The maximum power involves the minimum size gear
Assuming constant module for all gears in stage I.
The summation of teeth for each pair in stage I i.e. C I, can be
calculated as follows:
Assuming the min. available No. of teeth can be used in the
gearbox= 17 teeth
CI* fi/ (fi+ gi) = min. no. Of teeth= 17
CI* 26/126= 17

692

Figure (2) Speed Chart for 4 Speeds Gearbox with Two

Simplified Meshing Locations.

Actual Speed Calculations: The system is driven by single

speed electric motor
N1= N* Z1/Z2-7 * Z4-5/Z6 = 1000 * 28/54 * 65/65 = 518
rpm
N2 = N* Z1/Z2-7 * Z2-7/Z8 = 1000 * 28/54 * 54/76 = 369 rpm
N3 = N* Z3/Z4-5 * Z4-5 /Z6 = 1000 * 17/65 * 65/65 = 261 rpm
N4 = N* Z3/ Z4-5 * Z2-7 /Z8 = 1000 * 17/65 * 54/76 = 185 rpm

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

Table (5) Theoretical, Actual Speeds and Speed Deviation.

Table (6) Shows the Relation between the Suitable Transmission
Ratios and Progression Ratio for Gearboxes Deliver 6 speeds and
has Two Simplified Meshing Locations [8].

symbol
f
io
B
i1
i2
i3
i4
I5

Case (2):
Six Speeds Gearbox:
The kinematic diagram of conventional gearbox delivers 6
speeds has the form shown in Fig. (3-b).

1.06
0.565
0.63
0.56
0.475
1
0.934
0.89

1.12
0.647
0.82
0.65
0.46
1
0.89
0.79

Value
1.26
1.41
0.835 1.06
1.22
2.13
0.834 0.06
0.417 0.385
1
1
0.716 0.71
0.63
0.5

1.58
1.365
3.4
1.36
0.34
1
0.633
0.4

2
2.18
8.65
2.16
0.27
1
0.5
0.25

For the gearbox shown in Fig. (3), if two simplified meshing

locations are made, the kinematic diagram will be constructed.
The gearbox has two options to construct speed chart of the
gearbox. The two options are shown in Fig. (4), considering
f=1.26.

Figure (3) Kinematic Diagram for 6 Speed Gearboxes:

a- Conventional
b- Two Simplified Meshing Locations.

Actual Speed Equations:

N1 = N* Z1/ Z2* Z5/ Z6 = N* i1* i3
N2 = N* Z1/ Z2* Z7/ Z8 = N* i1* i4
N3 = N* Z1/ Z2* Z9/ Z10= N* i1* i5
N4= N* Z3/ Z4 * Z5/ Z6 = N* i2* i3
(24)
N5 = N* Z3/ Z4 * Z7/ Z8 = N* i2* i4
N6 = N* Z3/ Z4 *Z9/ Z10 = N* i2* i5
Where:
N = the input speed on the first shaft in the gearbox.
N1= highest speed at the gearbox spindle rpm
N6 = lowest speed at the gear box spindle rpm
i1, i2, i3, i4 and i5 = the transmission ratios for Z1/Z2 , Z3/Z4 ,
Z5/Z6 , Z7/Z8 and Z9/Z10 respectively
Assume:
N1 / N = i O
(25)
i1* i3= N1/ N= io
i1* i4= N2/ N= N1/ (N* f) = io/ f
i1* i5= N3/ N= N1/ (N* f2) = io/ f2
(26)
i2* i3= N4/N= N1/(N*f3) = io/ f3
i2* i4= N5/N= N1/(N*f4) io/ f4
Where:
io = the ratio between the highest speed on the gearbox spindle
to the input speed on the first shaft.
f = the base of progression transmission ratio
From equation (3)
i3/ i5 = f2
i3/ i4 = i4/ i5 = f
(27)

693

From the two options of speed chart the best is the first one,
which has the lowest number of nods. (Summation number of
intersection points in speed chart between the vertical lines
represent the shafts and the horizontal lines represent the speeds
calculated from the upper to the lowest point represent speed on
each shaft) [7]. Therefore, the first option will be taken in
consideration for design calculations of the gearbox.

Option (1) Summation of

Nods = 1+ 6 +7 = 14
(a)

Option (2) Summation of

Nods = 2+ 6 +7 = 15
(b)

Figure (4) Speed Charts for 6 Speeds Gearbox with Two

Simplified Meshing Locations for Single Speed Motor.

According to the kinematic diagram the following equations

can be derived:
a= (m* Z3/ 2 + m* Z4/ 2) = (m*Z4/ 2)/ (i2+ 1)
(28)
b= (m* Z5/ 2 + m* Z6/ 2) = (m* Z5/ 2)/ (1+ 1/i3)
(29)
a/ b = (i2+ 1)/ (1+1/ i3) = (i2* i3+ i3)/ (i3+1)
(30)
Also,
a= (m* Z1/ 2 + m* Z2/ 2) = (m* Z2/ 2)/ (i1+ 1)
(31)
b= (m* Z9/ 2 + m* Z10/ 2) = (m* Z9/ 2)/ (1+1/ i5)
(32)

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
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Vol-03, Issue-06, June 2015

a/b = (i1+ 1)/ (1+1/ i5) = (i1* i5+ i5)/ (i5+1)

(33)

From equations (3) & (6):

(i2* i3+ i3)/ (i3+1) = (i1* i5+ i5)/ (i5+1)
i1* i3= io
i1* i4= io/ f
i1* i5= io/ f2
i2* i3= Io/ f3
i2* i4= io/ f4
i2* i5= io/ f5
i1/ i2= f3
i3/ i4= i4/ i5= f
i3/ i5 = f2
i5* [f3* (f+1) io* (f2+ f+1)] =io
Let
f3* (f+1)- io* (f2+ f+ 1)= B=1.32
i5= io/ B= 0.63
i3=i5* f2= io* f2/ B= 0.1
i4= i3/ f = io* f2/ (B* f) = io* f / B = 0.79
i2= io / (f5* i5) = B/ f5= 0.416
i1= io / i3= B/ f2= 0.831

CI = 17* (Z3+ Z4)/ Z3

CI = 17* (52+ 125)/ 52 = 58 teeth
Z1= CI* f1/ (f1+g1) i.e.
Z1= 58 *831/1831 = 26
teeth
Z2= CI* g1/ (f1+g1) i.e.
Z2 = 32
teeth
Similarly:
Z3 = 58 * 52/177 = 17 teeth
Z4 = 41 teeth

(34)

(35)

(36)
(37)

(38)

io Calculation:
Z3/ Z6= Z3/ Z4* Z5/ Z6 = i2* i3 = io / f3
Z1/ Z10= Z1/ Z2* Z9/ Z10 = i1* i5 = io/ f2
Notice that i2 is the minimum reduction ratio
i2* i3= i2
i3= 0.1
io* f2/B= 1
io* f2= B = f3* (f+1) io* (f2+ f+ 1)
io = f3* (f+1)/ (2* f2+f+1) = 0.832

(39)
(40)
(41)
(42)
(43)
(44)
(45)

Number of Teeth Calculations:

Stage I:
According to equation (45) and speed chart shown in Fig. (4),
the following table can be constructed.

ii= fi/ gi
831/ 1000
0.416 = 52/ 125

N1= Nm* Z1/ Z2-9* Z5/ Z6 = 1000* 0.81 = 810

N2= Nm* Z1/ Z2-9* Z7/ Z8 = 1000* 0.64 = 640
N3 = Nm* Z1/ Z2-9* Z2-9 / Z10 = 1000* 0.52 = 520
N4= Nm* Z3/ Z4-5* Z4-5/ Z6 = 1000* 0.41 = 410
N5 = Nm* Z3/ Z4-5* Z7/ Z8 = 1000* 0.32 = 320
N6 = Nm* Z3/ Z4-5* Z2-9/ Z10 = 1000* 0.26 = 260

rpm
rpm
rpm
rpm
rpm
rpm

Table (8) Theoretical, Actual Speeds and Speed Deviation for Six
Speeds Gearbox Driven by Single Speed Electric Motor.

Table (7) Conversion of Transmission Ratio Fraction into Form

of Numerator and Denominator.
ij
i1= Z1/Z2
i2= Z3/Z4

Stage II:
Z2= Z9= 32
teeth
Z4= Z5= Z6= 41
teeth
CII = Z5+ Z6= 82
teeth
i4= Z7/Z8* 0.79
Z7= 0.79* Z8
Z7+ Z8= 82 teeth
Z8= 46 teeth
Z7= 36 teeth
i5= 0.63 = Z9/ Z10= 32/Z10
Z9= Z2= 32 teeth
Z10= 50 teeth
i1= io/ i3 =B/ f2= 0.831
i2= io/ (f5*i5) = B/ f5 = 0.416
i3= i5* f2 = io* f2/B = 1.0
i4= i3/ f = io* f/ B = 0.79
i5* io/ B = 0.63

(fi+ gi)
1831
177

The maximum power involves the minimum size gear

Assuming constant module for all gears in stage I.
The summation of teeth for each pair in stage I i.e. C I, can be
calculated as follows:
Assuming the min. available No. of teeth can be used in the
gearbox= 17 teeth
- Determine the lowest transmission ratio in stage I i. e. i2 =
52/125
- The driver gear for the lowest transmission ratio known as
Zmin.
- In this case i2= Z3/ Z4; Z3 = Zmin.
CI* Z3/ (Z3+ Z4) = 17

694

Similarly the same sequence can be followed to construct

gearboxes to give 8 and 9 speeds with two simplified meshing
Locations.

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

Using Double Speed Electric Motor to Drive Gearboxes with

Two Simplified Meshing Locations
For the gearbox shown in Fig. (1-b). assume the ratio between
the high and low speeds of electric motor Um equals:
Um = 3000/750 = 4

Fig. (6) Speed Chart for 12 Speeds Gearbox with Two Simplified
Meshing Locations Driven by Double Speed Electric Motor.

N1= Nmh* Z1/ Z2* Z5/ Z6= 3000* 0.81= 2430

N2= Nmh* Z1/Z2* Z7/ Z8= 3000* 0.64= 1920
N3= Nmh* Z1/Z2* Z9/ Z10= 3000* 0.52= 1560
N4= Nmh* Z3/Z4* Z5/ Z6 = 3000* 0.41= 1230
N5 = Nmh* Z3/Z4* Z7/ Z8= 3000* 0.32= 960
N6= Nmh* Z3/Z4* Z9/ Z10= 3000* 0.26= 780
N7 = Nml* Z1/Z2* Z5/ Z6 = 750* 0.81= 607.5
N8 = Nml* Z1/Z2* Z7/ Z8= 750* 0.64= 480
N9= Nml* Z1/Z2* Z9/ Z10= 750* 0.52= 39
N10= Nml* Z3/Z4* Z5/ Z6= 750* 0.41= 307.5
N11= Nml* Z3/Z4* Z7/ Z8= 750* 0.32= 240
N12= Nml* Z3/Z4* Z9/ Z10= 750* 0.26= 195
Where:
Nmh = High speed of the electric motor rpm
Nml = Low speed of the electric motor rpm

Fig. (5) Speed Chart for 8 Speeds Gearbox with Two Simplified
Meshing Locations Driven by Double Speeds Electric Motor.

Actual Speed Calculations:

N1= Nmh* Z1/ Z2-7* Z4-5/Z6 = 1000* 0.81 = 518
N2= Nmh* Z1/ Z2-7* Z2-7 /Z8 = 1000* 0.64 = 369
N3 = Nmh* Z3/ Z4* Z4-5/Z6 = 1000* 0.52 = 261
N4= Nmh* Z3/ Z4-5* Z2-7/Z8 = 1000* 0.41 = 185
N5 = Nml* Z1/ Z2-7* Z4-5/Z6 = 500* 0.32 = 129.5
N6 = Nml* Z1/ Z2-7* Z2-7/Z8 = 500* 0.26 = 92.25
N7= Nml* Z3/ Z4-5* Z4-5/Z6 = 500* 0.81 = 65.25
N8= Nml* Z3/ Z4-5* Z2-7/Z8 = 500* 0.64 = 46.25

rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm

rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm
rpm

Figures (7& 8) summarize the different cases of kinematic

diagrams, speed charts and improvement occurs on the gearbox
shape when two simplified locations and using single or double
speed electric motor to produce 8& 12 speeds respectively.

Table (9) Theoretical, Actual Speeds and Speed Deviation for 8

Speeds Gearbox Driven by Double Speed Electric Motor.

For the gearbox shown in Fig. (4-b) when it is derived by

double speed electric motor, the speed chart will be as shown
in Fig. (6).

695

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

3. Results and Discussions:

The present study clears that; the gearboxes have two simplified
meshing locations that produce output speeds in geometric
progression. The deviations of output speeds related to
theoretical speeds lie in the permissible limits. Two simplified
meshing locations leads to save two gears from each gearbox,
the saving ratios in gears are: 25, 20, 16.6, and 16.6 % for 4, 6,
8 & 9 speed gearboxes respectively. The two case studies for
achieving 8 and 12 speeds through 4 and 6 structural diagrams
gearboxes respectively are considered in this paper.
Improvement in gears utilization factor in gearboxes with two
simplified meshing locations and driven by single speed electric
motors is 16.7, 15, 13, 15 % if it is compared with the
conventional one for gearboxes 4,6,8 &9 speeds respectively,
while it is 33, 30, 27, 30% if the same systems are driven by
double speed electric motors. For gearboxes have Structural
diagrams and conventional construction, driven by single speed
electric motors 4, 6, 8& 9, if they are constructed with two
simplified meshing locations and driven by double speed
electric motors, the improvement in gears utilization factor
reached to 83, 90, 93& 105% respectively. The actual speeds,
speed deviations, and utilization factor of gears for various
gearboxes; (4, 6, 8& 9 speeds) using single or double speed
electric motors are calculated and listed in tables (8, 9, 10, 11,
12 and 13) and the relations are plotted in Figs. (9, 10 and
11).

Fig. (7) Kinematic Diagrams, Speed Char, Formula, and Some

Notes for 8 Speed Gearbox with 4 Options; (Conventional and
Two Simplified Meshing locations Driven by Single or Double
Speed Motor).

Table (10) Theoretical, Actual Speeds and Speed Deviation for 12

Speeds Gearbox Driven by Double Speed Electric Motor.

Table (11) Gear Utilization Factor (UF) for Various Gearboxes

Using Single and Double Speed Motors.
Fig. (8) Kinematic Diagrams, Speed Chart, formula, and Some
Notes for 12 Speed Gearbox with 4 Options; (Conventional and
Two Simplified Meshing Locations Driven by Single Speed
Motor) and (Conventional and Two Simplified Meshing
Locations Driven by Double Speed Motor).

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ISSN No: 2309-4893

International Journal of Advanced Engineering and Global Technology
I
Vol-03, Issue-06, June 2015

Table (12) Saved Gears, saving ratio and Gear Utilization Factor
(UF) for Various Gearboxes for Conventional and Two Simplified
Meshing Location.

For certain structural diagrams of conventional gearboxes to

output 4, 6, 8 and 9 speeds, this paper concerned with studying
the effect of single and double speed electric motors on the
delivered speeds. The construction of previous gearboxes with
two simplified locations, gear saving ratio on each case, gear
utilization factor, and its final improvement when using two
simplified meshing locations and driven by double speed
electric motor for each structural diagram are carried out.
Table (13) Gear Utilization Factor (UF) for Various Conventional
and Two Simplified Meshing Locations Gearboxes Driven by
Double Speed Motors.
Double Speed Motor
Speeds

Conv.

Simp.

UF Conv.

UF Simp.

2*4=8

1.333333

2*6=12

10

1.2

1.5

2*8=16

12

10

1.333333

1.6

2*9=18

12

10

1.5

1.8

Fig. (10) The Relation between Number of Speeds and Gear

Utilization Factor in Conventional and Two Simplified Meshing
Locations Gearboxes Driven by Single and Double Electric
Motors.

In summary, this paper explained the characteristics of the

multistage gear boxes with simplified meshing locations driven
by double speed electric motor design and proposed the
appropriate design algorithm which can be used in the future to
computerize the design process. This proposed design can be
carried out to find out the optimized design of the gearbox for
compact machine tools, helpful in saving time and reducing
complexity in gear box design. The proposed design can
increase design reliability and decreases time and cost by
minimizing unnecessary redesign iterations. The design
algorithm of using simulated strengthening to minimize the
geometrical volume of the gearbox, while satisfying spatial
constraints. The proposed algorithm has been applied to the
design of two gear boxes (8 and 12 speeds), and generated
considerably good design results in both aspects of the
dimensional and the configuration design. The designed
gearbox has been small-sized and minimized the number of
used gears, shafts, bearing and seals. The weight of a gear box
is proportional to the volume of the gears. This volume is
proportional to the sum of the gears width times the diameter
squared, of all the gears in the system. The proposed design
could result in light weight and ultra-light weight gear boxes.

Fig. (9) The Relation between Number of Speeds and Number of

Gears in Conventional and Two Simplified Meshing Locations
Gearboxes Driven by Single and Double Electric Motors.

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International Journal of Advanced Engineering and Global Technology
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Vol-03, Issue-06, June 2015

[9] Faisal S. Hussain, "Optimization of Gear Reduction Unit through Ray

Diagram", International Journal of Advanced Engineering and Global
Technology Vol-1, Issue-4, November 2013.
[10] Boidar Rosi, Aleksandar Marinkovic, Aleksandar Vencl, "Optimum
Design of Multispeed Gearboxes and Modelling of Transmission
Components", International Scientific Conference Heavy MachineryHM'05 Kraljevo, 28. June - 3. July 2005.
[11] Deb, Kalyanmoy and Jain, Sachin, Multi- Speed gearbox design using
multi objective evolutionary algorithms, Journal of mechanical
design Journals of mechanical Design, Vol. 125, pp 609- 619,
September 2003.
[12] M. A. Nasser, F. R. Gomaa, M. A. Asy, Ahmed Deabs, " Computer Aided
Design of Multi-Stage Gearboxes|, International Journal of Advanced
Engineering and Global TechnologyVol-02, Issue-12, December 2014.
[13] M. A. Asy, "Design of Machine Tool Gearboxes Driven by Double Speed
Electric Motors", International Journal of Advanced Engineering and
Global Technology Vol-03, Issue-03, March 2015.

Fig. (11) The Relation between Number of Speeds, Gear

Utilization Factor for Gears in Case of Conventional and Two
Simplified Meshing Locations Gearboxes and Gear Max. UF
Improvement.

Conclusions:
1. Novel design of gearboxes with two simplified meshing
locations driven by double speed electric motor gives
output speeds in geometric progression is presented.
2. Gearboxes with two simplified meshing locations reduce
the number of used gears which improve its saving ratio.
The saving ratios lie between 16.7 and 25 % and reduces
the shaft lengths, gearbox size and cost.
3. Improvement in gears utilization factor in gearboxes with
two simplified meshing locations driven by single speed
electric motor is significant lies between 13and 15%, but
it is more significant if the same systems are driven with
double speed motors ranging between 27 and 33% for
gearboxes under study.
References
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