Design procedure for Gear Box

Follow this procedure to have idea about how to design a complete Gear Box with each
component's individual design.

1. Determine the maximum and minimum speeds of the output shaft. Calculate the
number of steps or speed reduction stages for this range. This depends on the
application as well as space optimization. Higher reduction stages require more
space because of more number of gears and shafts requirements.

2. Select the type of speed reducer or gear box based on the power transmission
requirements, gear ratio, positions of axis, space available for speed reducer.
Also make sure that for low gear ratio requires single speed reduction. Select
worm gears for silent operation and bevel gears for intersecting axis.

3. Determine the progression ratio which is ratio maximum speed and minimum
speed of output shaft of Gear Box. The nearest progression ratio should be a
standard one and is taken either from R 20 or R 40 series.

4. Draw the structural diagram and kinematic arrangement indicating various

arrangement possibilities during speed reduction or increment.

5. Select materials for gears so that gear should sustain the operating conditions
and operating load. Normally cast iron is chosen for housing and cast steel or
other alloy can be selected as per the load requirements.

6. Note down the maximum power out put in Horse Power (H.P) or transmission
power and revolution per minute of shart i.e. rpm of each shaft.

7. Determine the centre distance between the driven and driver shaft based on the
surface compressive stress.

8. Determine the module of gear by beam strength as well as fix the number of
teeth required.

9. Calculate the diameter of the shafts by torque requirements and bending moment
considerations.

10. Calculate the key size, shape or type of transmission keys for each gears.

11. Select appropriate fit and tolerance for mating parts like shaft and gear.

12. Select bearings types based on the loading and operating conditions. Also make
sure to include consideration of maximum speed and expected life of gears and
gear box. Normally ball bearings and roller bearings are used for small size of
gearbox because they have lower thrust requirement due to low speed reduction.

13. Make the shaft stepped or provide collar to prevent axial displacement of bearing
and gear.

14. Provide suitable clearance between gears and walls of the housing of gear box
and based on this considerations design the casing/housing of gearbox.

15. Complete the design of casing. One should Provides fins if necessary to have
increased heat transfer by convection and conduction. Put inspection hole/man
hole as well as drain hole to drain lubricating oil. Also provide oil level indicator to
have proper amount of oil during operation, if not put, this will lead to failure of
gear and shaft due to over heating or due to frictional failure. Provide
transportation hooks for transporting the gearbox from one place to another or
during installation and maintenance. Also design gear changing lever
accordingly.

16. Draw neat and clean working drawings in suitable software like AutoCAD, Pro
Engineer etc., indicating required details during manufacturing or assembly.

17. One can also perform finite element analysis of the complete Gear Box after it
completely designed.