GEAR BOX

A 2*2 driver is requirement to the be design for transmitting speed starting from 400 rpm
with a geometric ratio of 1.4. draw a suitable standard database and speed diagram also
the draw the layout of the gearbox and database determine the no. of the teeth on each
gear. Plot the deviation diagram and within permissible limit. assume belt drive is used
for rating the desired speed of input from the motor shaft.
The design would be for a 2 stage a speed gearbox;
N1= 400 rpm
= 1.4
4 speed on the output shaft can be calculate as follows;
N1

= 400 rpm

N2

N3
N4

=
=

N1

= 400*1.4 = 560rpm

N2
N3

= 560*1.4 = 784rpm
= 784*1.4 = 1097.6rpm

Structure diagram;

Check the suitable or the longesrt situation;


Ig = <= 8

So the structure diagram is suitable we now draw the diagram of speed ray diagram

From speed ray diagram the input of the stages is 1097.8rpm. this wand for gear A and B, output
N3
speed for the stages can from the speed diagram,
=784rpm and =1097.6rpm which
would be output speed for a and b.
Z0'
Z0
Zb'
Zb
Za'

Na
N a'

Nb
N b'

1097 . 4
784

= 1.4

1097 . 6
1097 . 6

=1

Z0

= 1.4
Zb

Zb'

Za

So calculate the teeth on each gear;

Za
Za'
= 1.4

Za'

25
27
28

= 2.4

Za + Za'

Za
18
19
20

I0 '

and
Za

= 2.4

Zb

Zb

I b'

1.2

Zb' = Zb .

Za
43
46
48

22
23
24

44
46
48

In same cases to have component gear box. Analysis on the gear ratio can be tha in such call the
corrected value of each gear ratio may have to be worked out.
Let,

Zb'
Zb
Zb'
Zb

Nc
N c'

Na
N a'

1097 . 6
1097 . 6

=1

1097 . 6
50

= 1.94

Zc = Zc
Za1.96 Za = Zd + Zc = Za+ Za
Zc = 1.48Za
Za
18
19
20
Za = 19

Za=1.96Za
36
37
40
Za = 37

Za+Za
54
56
60

Zc=1.48Zc
27
28
30

Zc+Zc
54
56
63

Remark
Input speed
Mini speed on
shaft
Input speed
Mini. Speed on
shaft
Spindle gear N1
Spindle gear N4
Spindle gear N1
Spindle gear N0

Zc = Zc = 28

Gear
a
a

Gear ratio
1.4

Actual gear
1097.6
786

Shaft
1
2

b
b

1
1

1097.6
1097.6

1
1

C
C
D
D

1
1

784
1097.6
784
404.1

3
3
3

1.94

Parameter direction should be has than

10(-1) = 10(1.4-1) = 1.4
Actual the direction diagram consist of the following data,
Actual speed

Theoretical speed

N act N
% AN=
N th

th

* 100

404.1
565.8
784
1097.6

400
560
784
1097.6

1.025
1.036
0
0

A six speed gear boxes is to be designed for machine tool drive for nine spindle speed ranging
from 150 rpm to 1000 rpm. If the gear box is driven by 5 Kw, 1000 rpm electric motor through
the belt drive.
1. Draw the speed ray diagrammed;
2. Determine the no. of teeth on gear;
3. Draw the gearing diagram
Solution;
Given data;
Z=6;
NMIN=150RPM
NMax=1000RPM;
Nem=1000RPM

p=5Kw

1. Range ratio(Rn)
R n=

nmax 1000
=
=6 .67
nmin 150

2. GEOMATRIC PROGRESSION RATIO,( ()

= Rn

1
(Z1 )

1
( 61 )
==

6 . 667

=1 . 461

3. SPINDLE SPEED(nk)
Speed step
1

Expression
N 1=N 1

N 1=N 1 1

N 1=N 1

Speed
N1=150
N2=219.15
2

N3=320.5

N 1=N 1

N4=468.5

N 1=N 1

N5=684.5

N 1=N 1

N6=1000

4. NUMBER OF STAGE OF GEAR BOXES;

Z=P1P2
6=2*3
Hence 2 stage gear box is selected with one stage of 2 speed and othe stage of 3 speed steps
5. STRUCTURATL FORMULAE;
The structural formula for gear box is given by,
Z=P1(X1)P2(X1)
Z=2(1)3(2).(A)
Equation (a) gives optimum structural formula for six speed gear box
6. SPEED RAY DIAGRAM;
7. KINEMATIC (GEARING) DIAGRAM OF GEAR BOX;
8. DIAMETERS OF BELT PULLEYS;
Let n1=speed of input shaft
Nem=speed of electric motor shaft
D1= dia of belt pulleys on input shaft;
Dem= dia of belt pulleys on electric motor shaft shaft;
log 10 ni=log 10 n3 +

log 10
2
= log 10 320. 5+

=
log 10 ni=2 .588
Ni= 387.4 rpm
nem
Di
ni = D em
Di
1000
=
387 . 4
D em

log 10 (1 . 461)
2

D i=20581 Dem
Hence

D em =112 mm

Di = 290mm