Machine-Design - Gear Shaft Problem

MEMB 333 | Machine Design 1
INTRODUCTION

Gear box is one of the important component is in the wind turbine. It is situated between
the main shaft and the generator. Its task is to increase the slow rotation speed at main shaft to
the generator shaft and convert the rotational motion into another type of energy. The wind
turbine gear box is not like a normal car gear box that can change the speed. A typical wind
turbine gearbox will always have a constant ratio and a speed increasing ratio.
In a gear box, shaft plays an important role as the power transmitter. It will connect the
hub of the blade at the input to the mechanical generator at the output to produces electricity. For
a two stage gear train design, shaft is like connector that connects the gears in stage to the gears
in stage 2. Hence, the shaft designed must be able to withstand the high torque input and the load
due to the rotation at the gear.
In order to mount the shaft on the housing, bearing is needed in the design. There are
many types of bearing such ball bearing, roller bearing, sleeve bearing, diamond bearing and
fluid bearing. However, for this project, the only type of bearing allowed in the design is a roller
bearing. A roller bearing is a noisy bearing for a rotating shaft however ball bearing is less
sensitive to interruptions of lubrication and no self excited instabilities. It also can seal lubricant
within bearing and lifetime-lubricate.
The aim of the project is to design a gear box that will transmit power at the input to the
generator at the output. In evaluating this design, the following specifications are considered
such as factor of safety, gear ratio, weight/size, shaft arrangement, loading, life, reliability and
weak link design.


DESIGNING GEAR

Given:
1. Overall ratios, M
G
= 30 (speed increase)
2. Number of stage = 2
3. Pressure angle, = 25
o
C

Finding teeth:
Gear set ratio, M
GS
= M
G
1/2
= 30
1/2
= 5.477
Since the number of teeth on each gear must be an integer, see how close it can come to the
5.477:1 gearset ratio with integer combination of teeth starting with the smallest possible pinion
based on the table 11.4 (3
rd
edition)
y 12 (5.477) = 65.727
y 13 (5.477) = 71.204
y 14 (5.477) = 76.681
y 15 (5.477) = 82.158
y 16 (5.477) = 87.636

The fourth of these (82.158) will be very close to the gear set ratio when rounded to an integer.
Hence, the number teeth:
y Number of teeth for pinion, N
P
= 15
y Number of teeth for gear, N
g
= 82


Given:
1. Overall ratio, M
G
= 30
2. Input rotational velocity,
= 120 rpm
3. Pinion teeth, N
P
= 15
4. Gear teeth, N
g
= 82
5. Wind velocity, V = 10 m/s
6. Turbine blade efficiency, = 0.3
7. Air density, = 1.24 kg/m
3

Finding power transmitted through the gear set:
Area covered by the turbine blade =
= 45 m
2

Power,

= 8.469 kW 11.4 hp

Finding gear speeds:

y Stage 1:

= 120 rpm

= 656 rpm
y Stage 2:

= 656 rpm
= 3586.133 rpm

Finding the transmitted shaft power:
y Input shaft :

5987.409 lb-in
y Middle shaft :

1095.258 lb-in
y Output shaft :

200.352 lb-in


Assuming all the gears and pinion are made of the same material and the same hardness,
hence the material bending fatigue strength and material surface fatigue strength will be the same
for all gears and pinions.

Finding Material Bending Fatigue Strength

Given:
1. Material: Steel through hardened 270 HB
2. Input rotational velocity,
= 120 rpm
3. Operating temperature = 70
o
C
4. Reliability is 90%

An estimated of the uncorrected surface fatigue strength can be made from the curve of figure
11-25. For AGMA Grade 2 steel:
S
fb
= 6235 + 174HB-0.126HB
2
= 6235 + 174(270)-0.126(270
2
) = 4402.6 psi

The life was calculated based on the input rotational velocity which is 120 rpm. The system is a
continuous operating mechanism that operates continuously for years.
Life Cycles, N = 125 rpm (10 years) (365 days) (24 hours) (60 minutes) = 6.307 10
8
cycles
Life Factor, K
L
= 1.3558N
-0.0178
= 1.33558 (6.307 10
8
)
-0.00178
= 0.945
Reliability Factor, K
R
= 0.85 (reliability is 90%)
Temperature Factor, K
T
= 1 (operating temperature is less than 121
o
C 250
o
F)

Hence, the bending fatigue strength for the chosen material is:
S
fb
=
= 48950.56 psi

Finding Material Surface Fatigue Strength:
Given:
1. Material: Steel through hardened 270 HB
o
C
4. Life Cycles = 6.307 10
8
cycles

An estimated of the uncorrected surface fatigue strength can be made from the curve of figure
11-27. For AGMA Grade 2 steel:
S
fc

= 27000 + 364 HB = 27000 + 364 (270) = 125280 psi
Life factor, C
L
= 1.4488N
-0.023
= 0.909
Hardness Ratio Factor, C
H
= 1 (same material and hardness for all gears and pinions)
Reliability Factor, K
R
= 0.85 (reliability is 90%)
Temperature Factor, K
T
= 1 (operating temperature is less than 121
o
C 250
o
F)

Hence, the surface fatigue strength for the chosen material is:
S
fc
=
= 133975.906 psi


Finding Bending Stress
Given (already calculated):
1. Pressure angle = 25
o
C
2. Reliability = 90%
3. Quality index = 9
4.
= 120 rpm
5.
= 656 rpm
6.
= 3586.133 rpm
7. Gear teeth = 85
8. Pinion teeth = 15
8
cycles
10. Assuming P
d
= 7
11. Input torque:
= 5987.409 lb-in
12. Middle torque :
= 1095.258 lb-in
13. Output torque :
= 200.352 lb-in

From the table 11-13, the value of J for pinions and gears are:
J
P
= 0.28 and J
G
= 0.37

Bending Stress at Stage 1 (Gear 1):
Bending stress,

y Transmitted load,

y Application factor, K
a
= 1 (choose from table 11-17)
y Load distribution factor, K
m
= 1.7 (assumption)
y Idler factor, K
i
= 1 (no idler)
y Size factor, K
s
= 1 (AGMA recommendation)
y Rim thickness factor, K
b
= 1 (solid)


The velocity factor K
v
is based on the value of quality index Q
v
and pitch line velocity V
t
.
) =383.349 ft/min
B =
= 0.52
A = 50 + 56 (1- B) = 50 + 56 (1- 0.52) = 76.88

0.891

Hence, the bending stress at the input stage 1 (gear 1) is,
psi

Bending Stress at Stage 1 (Pinion 1):
Bending stress,

y Transmitted load,

a
m
= 1.7 (assumption)
y Idler factor, K
i
= 1 (no idler)
y Size factor, K
s
b
= 1 (solid)


v
v
t
.
) = 368.015 ft/min
B =
= 0.52
A = 50 + 56 (1- B) = 50 + 56 (1- 0.52) = 76.88

0.891

Hence, the bending stress at the stage 1 (pinion 1) is,
psi

Bending Stress at Stage 2 (Gear 2):
Bending stress,

y Transmitted load,

a
m
= 1.7 (assumption)
y Idler factor, K
i
= 1 (no idler)
y Size factor, K
s
b
= 1 (solid)


v
v
t
.
) =2011.819 ft/min
B =
= 0.52
A = 50 + 56 (1- B) = 50 + 56 (1- 0.52) = 76.88

0.787

Hence, the bending stress at the stage 2 gear 2 is,
psi

Bending Stress at Stage 2 (Pinion 2):
Bending stress,

y Transmitted load,

a
m
= 1.7 (assumption)
y Idler factor, K
i
= 1 (no idler)
y Size factor, K
s
b
= 1 (solid)


v
v
t
.
) = 2011.856 ft/min
B =
= 0.52
A = 50 + 56 (1- B) = 50 + 56 (1- 0.52) = 76.88

0.787

Hence, the bending stress at the stage 2 (pinion 2) is,
psi


Finding Surface Stress
1. Pressure angle = 25
o
C
3. Quality index = 9
4.
= 120 rpm
5.
= 656 rpm
6.
= 3586.133 rpm
7. Gear teeth = 85
8. Pinion teeth = 15
8
cycles
10. Assuming P
d
= 7
11. Input torque:
= 5987.409 lb-in
12. Middle torque :
= 1095.258 lb-in
13. Output torque :
= 200.352 lb-in

Surface stress,

y Face width, F = 12/7 = 1.714 in
y Application Factor, C
a
= 1 (from table 11-17)
y Load distribution factor, C
m
= 1.7 (from table 11-16)
y Dynamic Factor, C
v
= K
v
= 0.891
y Size factor, C
s
y Surface finish factor, C
f
= 1 (made by conventional method)
y Gear poisson ratio, V
g
= 0.28
y Pinion poisson ratio, V
p
= 0.28
y E
p
= E
g
=

Elastic Coefficient, C
p
=


The pitting geometry factor I is calculated for a pair of gear mesh. Since we have two
meshes (stage 1 and stage 2), there will be two different values W
t.

Surface Stress at Stage 1 (between the surface of gear 1 and pinion 1):
Transmitted load,
= 1022.24 lb
cos
cos
cos
cos
Csin
sin
sin
in

Hence, the geometry factor I is,

cos

cos

So, the surface stress at stage 1,


Surface Stress at Stage 2 (between the surface of gear 2 and pinion 2):
Transmitted load,
cos
cos
cos
cos
Csin
sin
sin
in

Hence, the geometry factor I is,

cos

cos

So, the surface stress at stage 2,


Finding Factor of Safety
1. Material bending fatigue strength, S
fb
= 48950.56 psi
2. Material surface fatigue strength, S
fc
= 133975.906 psi

Factor of safety for each gear (bending):
Stage 1:
N
g1
=

N
p1
=

Stage 2:
N
g2
=

N
p2
=

Factor of safety for each stage (surface):
Stage 1:

Stage 2:


DESIGNING SHAFT
In the gear box, there were 3 shaft needed for the gear box to function. The first shaft is
situated at the input which will connect the first gear to the turbine blade. The second shaft is
situated between the stage 1 and stage 2 of the gear train. The last shaft is situated at the output
which will connect the output pinion to the generator.
Shaft 1 (at input)
Given:
2. Load transferred, W
t
= 1022.24 lb
3. Input torque, T = 5987.409 lb-in
4. Material is SAE/AISI 1095 Carbon Steel
5. Yield Strength = 118 kpsi
6. Ultimate Tensile Strength = 183 kpsi

Assuming the input shaft length is 8 inch (excluding the protruding 4 inch out of front of gear
box). Hence, we can find the maximum moment exerted on the shaft based on the W
t
from the
gear.

Since, the resulting force of A and B are symmetrical, hence the force A and B is equal to
each other and half of the load force, W
t
. So, the value of force A and B is 511.12 lb.
F
A
= F
B
= 511.12 lb

4 inch
A B
1022.24 lb
4 inch

Moment Diagram:

Shaft Under Dynamic Loading
The objective of the design is to design a shaft under dynamic loading with minimum
factor of safety, FS
f
= 2.0.

Assumption:
The torque and moment on the shaft are both varying with time in repeated fashion ( the
alternating and mean component are of equal magnitude).
Given:
2. FS
f
= 2.2
3. Mean Moment = Alternating Moment = 2044.48 lb-in
4. Mean Torque = Alternating Torque = 5987.409 lb-in
o
C
6. Surface finish = Machine/Cold Rolled

0
2044.48
8 4
Distance (in)
Moment (lb-in)

Corrected fatigue strength, S
e
= C
load
C
siza
C
surf
C
temp
C
reliab
S
e

y Loading effects, C
load
= 1 (bending effect)
y Size effect, C
size
= 0.7
y Surface effect, C
surf
= 0.68 (from table 6-3)
y Temperature effect, C
temp
= 1 (operating temperature = 70
o
C)
y Reliability factor, C
relian
= 0.897 (table 6-4)

Uncorrected fatigue strength, S
e
= 0.5 S
ut
= 0.5 (183 kpsi) = 91.5 kpsi
Corrected fatigue strength,
si si

In order to find the diameter suitable for the factor of safety equal to 2.2, the value of notches
sensitivity and stress concentration need to be determined first. The steps to find the these values
are as below:
Notch Sensitivity,

(the value of is found from table 6-6)

Assuming the value of K
t
= 3.5 and K
ts
= 2

Since, K
si
and 7448.9 psi < 118 kpsi (S
y
)
So the value of K
f
= K
fm
and K
fs
= K
fsm
.

Lastly, by substituting all the variables found above into the equation, the diameter of the shaft at
factor of safety equal to 2.2 can be found.

Shaft diameter, d
= 1.846 inch
From the preliminary calculation, the reasonable size of diameter for the shaft can be
determined. Based on figure 10-23, the next largest standard ball bearing diameter to shaft 1
(1.846 inch diameter calculated) for point A and B is 1.97 inch. Hence, we will chose 1.97 inch
as the shaft diameter for shaft 1.
Shaftiametei


Shaft 1 Under Static Loading:
The objective of the design is to design a shaft under static loading with minimum factor
of safety, FS
y
= 2.0.
Given:
1. Moment maximum = 2044.48 lb-in
2. Input torque = 5987.409 lb-in
3. Diameter of the shaft = 1.97 inch (from the dynamic loading analysis)
Bending stress,
si
Shear stress,
si
si
si
si
Hence, the Von Mises Stress is,

si
Hence, the factor of safety for static loading is,


Shaft 2 (middle shaft)
Given:
y Reliability is 90%
y Load at pinion1, W
tp
= 1022.24 lb
y Load at gear2, W
tg
= 186.995 lb
y Torque, T = 1095.258 lb-in
y Material is SAE/AISI 1095 Carbon Steel
y Yield Strength = 118 kpsi
y Ultimate Tensile Strength = 183 kpsi

We can find the maximum moment exerted on the shaft based on the W
t
from the each gear.

From the free body diagram, the force at A and B is found as shown below:

855.191 lb and A = 354.044 lb

1022.24 lb 186.995 lb
B
A
3 inch
3 inch
9 inch

Moment Diagram:

Shaft 2 Under Dynamic Loading
f
= 2.0.

Assumption:
The torque and moment on the shaft are both varying with time in repeated fashion (the
alternating and mean components are of equal magnitude).
Given:
y Reliability = 90%
y FS
f
= 2.0
y Mean Moment = Alternating Moment = 2565.573 lb-in
y Mean Torque = Alternating Torque = 1095.258 lb-in
y Operating temperature = 70
o
C
y Surface finish = Machine/Cold Rolled

3 12 15
2565.573
1062.132
0
Distance (in)
Moment (lb-in)

e
= C
load
C
siza
C
surf
C
temp
C
reliab
S
e

load
y Size effect, C
size
= 0.7
y Surface effect, C
surf
= 0.68 (from table 6-3)
temp
o
C)
relian
= 0.897 (table 6-4)

e
= 0.5 S
ut
= 0.5 (183 kpsi) = 91.5 kpsi
si si

are as below:
Notch Sensitivity,


t
= 3.5 and K
ts
= 2

Since, K
si
and 7448.9 psi < 118 kpsi (S
y
)
So the value of K
f
= K
fm
and K
fs
= K
fsm
.


Shaft diameter, d

= 1.55 inch

(1.55 inch diameter calculated) for point A and B is 1.57 inch. Hence, we will chose 1.57 inch as
the shaft diameter for shaft 2.
Shaftiametei


of safety, FS
y
= 2.0.
Given:
y Moment maximum = 2565.573 lb-in
y Input torque = 1095.258 lb-in
y Diameter of the shaft 2 = 1.57 inch (from the dynamic loading analysis)
Bending stress,
si
Shear stress,
si
si
si
si


si
Hence, the factor of safety for static loading at middle shaft is,

si
si


Shaft 3 (at output)
Given:
y Reliability is 90%
y Load at output pinion, W
tp
= 186.995 lb
y Torque, T = 5987.409 lb-in
y Material is SAE/AISI 1095 Carbon Steel
y Yield Strength = 118 kpsi
y Ultimate Tensile Strength = 183 kpsi

Assuming the input shaft length is 8 inch (excluding the protruding 2 inch out of rear of gear
box). Hence, we can find the maximum moment exerted on the shaft based on the W
t
from the
gear.

Since, the resulting force of A and B are symmetrical, hence the force A and B is equal to
each other and half of the load force, W
t
. So, the value of force A and B is 93.498 lb.
F
A
= F
B
= 93.498 lb
Moment Diagram:

4 inch
A B
186.995 lb
4 inch
0
373.992
8 4
Distance (in)
Moment (lb-in)

Shaft Under Dynamic Loading
f
= 2.0.

Assumption:
The torque and moment on the shaft are both varying with time in repeated fashion ( the
alternating and mean component are of equal magnitude).
Given:
y Reliability = 90%
y FS
f
= 2.2
y Mean Moment = Alternating Moment = 373.992 lb-in
y Mean Torque = Alternating Torque = 200.352 lb-in
y Operating temperature = 70
o
C
y Surface finish = Machine/Cold Rolled

e
= C
load
C
siza
C
surf
C
temp
C
reliab
S
e

load
y Size effect, C
size
= 0.7
y Surface effect, C
surf
= 0.68 (from table 6-3)
temp
o
C)
relian
= 0.897 (table 6-4)


e
= 0.5 S
ut
= 0.5 (183 kpsi) = 91.5 kpsi
si si

are as below:
Notch Sensitivity,


t
= 3.5 and K
ts
= 2

Since, K
si
and 7448.9 psi < 118 kpsi (S
y
)
So the value of K
f
= K
fm
and K
fs
= K
fsm
.

Shaft diameter, d
= 0.85 inch

(0.85 inch diameter calculated) for point A and B is 0.98 inch. Hence, we will chose 0.98 inch as
the shaft diameter for shaft 3.
Shaftiametei

of safety, FS
y
= 2.0.
Given:
y Moment maximum = 373.992 lb-in
y Input torque = 200.352 lb-in
y Diameter of the shaft = 0.98 inch (from the dynamic loading analysis)
Bending stress,
si
Shear stress,
si
si
si
si



si
Hence, the factor of safety for static loading is,

Finding Angular Deflection For Each Shaft
Given:
y Torque at shaft 1 (input) = 5987.409 lb-in
y Torque at shaft 2 (middle) = 1095.258 lb-in
y Torque at shaft 3 (output) = 200.352 lb-in
Shaft 1:
ia 0.158
o

Shaft 2:
ia 0.135
o

Shaft 3:
ia 0.087
o


Finding Deflection For Each Shaft
Given: E = 30 Mpsi
Shaft 1:

1.

2.
C
3.

C C
C C
At boundary condition:
y When x = 0, y = 0
y When x = 8 inch, y = 0
By substituting the boundary condition into equation (3), the value of C1 and C2 are:
y C1 = -4089.816
y C2 = 0
Substituting the value of C1 into equation (2), the location of Ymax can be found:
y
C
Hence, x = 4 inch
Hence, to find the value of Ymax at x = 4 inch using equation (3):
y
C C
y
-0.00049 inch (downward)

4 inch
A B
1022.24 lb
4 inch

Shaft 2:

1.

2.
C
3.
C C
y When x = 0, y = 0
y C1 = -9377.5446
y C2 = 0
y

Hence, x = 9.617 inch
Hence, to find the value of Ymax at x = 9.617 inch using equation (3):

y
C C
y

1022.24 lb 186.995 lb
B
A
3 inch
3 inch
9 inch

Shaft 3:

1.

2.
C
3.

C C
C C
y When x = 0, y = 0
y C1 = -747.984
y C2 = 0
y
747.984
Hence, x = 4 inch
Hence, to find the value of Ymax at x = 4 inch using equation (3):
y
C C
y

4 inch
A B
186.995 lb
4 inch

DESIGNING BEARING
There are many type of bearing such plain bearing, jewel bearing, fluid bearing, flexure
bearing and magnetic bearing. For this gear box designed, the chosen type of bearing is ball
bearing. There are 6 bearings to support the shafts. There will be 2 bearings at each shaft.
Ball bearing was chosen at all shafts because ball bearing is less sensitive to interruptions
of lubrication and no self excited instabilities. It also can seal lubricant within bearing and
lifetime-lubricate.
Ball bearings at shaft 1

From the diagram above, the force at bearing A and bearing B is equal (symmetrical).
Since, the bearing at point A and B is at the same diameter of shaft, the same type of ball bearing
will be used at those points.
Given:
y Diameter of the shaft, d = 1.97 in
y Force at Bearing A = 511.12 lb
y Force at Bearing B = 511.12 lb
y Type of lubrication = SAE Engine 50
y Thrust load are negligible
y Operating speed = 120 rpm

4 inch
A B
1022.24 lb
4 inch

From figure 10-23 (in the text book), a #6310 bearing with 1.97 inch inside diameter was
chose to support shaft 1 at points A and B. Its dynamic load rating is C = 10600 lb. The static
load rating C
o
= 8150 lb. The static applied load of 511.12 lb is obviously below the bearings
static rating.
From table 10-5 (in the text book), the factor for a 1% failure rate (reliability 99%), K
R
=
0.21.
Since the load at point A and B is equal and the equivalent load is simply the applied
radial load, so the bearing fatigue life is same for both bearing A and B. The calculation is as
below:

millionsofievs
ievs

ievs

From figure 10-23 (in the text book), this bearing limiting speed is 6000 rpm. Well above
the operating speed of 125 rpm.



From the diagram above, the force at bearing A and bearing B is unequal (asymmetrical).
Since the load at B is larger than at A, one design can be created for B and used also at A. Shaft
diameter for both A and B is 1.57 in.
Given:
y Rotational speed, = 656 rpm
y Thrust load are negligible

chose to support shaft 2 at points A and B. Its dynamic load rating is C = 7350 lb. The static load
rating C
o
= 5300 lb. The maximum static applied load of 844.191 lb is obviously below the
bearings static rating.
R
=
0.21.

1022.24 186.995
B
A
3
3
9

Note that equivalent load is simply the applied radial load due to the absence of the thrust
load. For the larger reaction load of 844.191 at point B, the projected life calculation is as below:

millionsofievs
ievs

ievs
From figure 10-23 (in the text book), this bearing limiting speed is 7500 rpm. Well above
the operating speed of 656 rpm.


From the diagram above, the force at bearing A and bearing B is equal (symmetrical).
Since, the bearing at point A and B is at the same diameter of shaft, the same type of ball bearing
will be used at those points.
Given:
y Rotational speed, = 3586.13 rpm
y Thrust load is negligible

chose to support shaft 3 at points A and B. Its dynamic load rating is C = 3800 lb. The static load
rating C
o
= 2550 lb. The static applied load of 93.4 lb is obviously below the bearings static
rating.
4 inch
A B
186.995 lb
4 inch

R
=
0.21.
Since the load at point A and B is equal and the equivalent load is simply the applied
radial load, so the projected bearing fatigue life is same for both bearing A and B. The
calculation is as below:

millionsofievs
ievs

ievs
From figure 10-23 (in the text book), this bearing limiting speed is 11000 rpm. Well
above the operating speed of 3586.133 rpm.


DESIGNING SHAFT KEYS
In engineering application, key is a machine part to connect a rotating machine element
to a shaft. During this connection, the key will avoid a relative rotation between the two parts
and allowing torque to be transmitted.
A keyway must be manufactured either on the shaft and rotating machine for it to
function. Keys for this design are located at each gear. The keys will be used as a medium to
transfer the torque from the shaft to the gear.

Key at shaft 1(at the input)
The input shaft key was design to get a yield factor of safety of about 1.5, to make it the
weakest link in the system. Failure to occur at this key and if accidental overload occur it will
protect the rest of the gear box.
Given:
1. Yield factor of safety, N
s
=1.55
2. Alternating torque, T
a
= 5987.409 lb-in
3. Mean torque, T
m
= 5987.409 lb-in
4. Shaft diameter = 1.97 inch
5. Parallel key type
6. Yield strength = 118000 psi

Width of the key is depending on the shaft diameter. Based on the Table 9-2, the suitable
key width for a shaft diameter of 1.97 inch is 0.5 inch
Yield safety factor,
si


The force (mean and alternating) acting on the key is found from the torque dividing by the shaft
radius:
lb
lb
The bearing stress on the key is compression and thus can be considered a static load. It is
calculated using the maximum force on the key:

Hence, the length of the key, l = 0.64 in

In conclusion, to get a yield strength factor of safety (N
s
) equal to 1.55, the width and the length
of the shaft is 0.5 in and 0.64 in respectively.


Keys at shaft 2(at pinion and gear)
There will be 2 keys at shaft 2. The first key will connect the shaft to the pinion1 and the
other key will connect the shaft to the gear 2. Both key will transfer the same torque at the same
shaft diameter. Hence, the designing of both keys at shaft 2 will be the same.

Given:
a
= 1095.258 lb-in
2. Mean torque, T
m
= 1095.258 lb-in
6. Ultimate Tensile Strength = 183000 psi


The force (mean and alternating) acting on the key is found from the torque dividing by the shaft
radius:
lb
lb
Assuming a key length of 0.64 in and calculate the alternating and mean stress components:
si
si


The von mises stress is found as shown below:
si
si
Hence, the fatigue safety factor is:


si


Keys at shaft 3(at pinion)
There will be one key at shaft 3. The key will connect the shaft to the pinion 2. The
required factor of safety for both fatigue and yield are minimum 2.0

Given:
a
= 200.352 lb-in
2. Mean torque, T
m
= 200.352 lb-in
6. Ultimate Tensile Strength = 183000 psi


The force (mean and alternating) acting on the key is found from the torque dividing by
the shaft radius:
lb
lb
Assuming a key length of 0.64 in and calculate the alternating and mean stress components:
si
si


The von mises stress is found as shown below:
si
si
Hence, the fatigue safety factor is:


si


LUBRICATION SELECTION
Selection of lubrication oils for gearbox application should be done with guidance from
the specialist supplier. The basic background guidance of gearbox lubrication is shown as below:
y For high speed gears at lower temperature (-10
o
to 16
o
C)
- low viscosity oil should be selected such as ISO VG 46.
y For medium speed at lower centre distances (less than 200mm)
- viscosity grade range of ISO VG 68 - ISO VG 100 is reasonable.
y For medium speed at lower centre distances (more than 200mm)
- a viscosity grade range of ISO V is acceptable

The following equation from provides a method for verifying the required viscosity for a
specific gear based on the operating velocity:
Viscosity,
40
=
7000
Vt
0.5

The maximum viscosity will occur at the lowest pitch line velocity which is at the output
(stage 2), which is 3.312
reyns. Based on the figure 10-1 (in the text book), the suitable
lubricants for the gears is:
SAE GEAR 80W lubricant at 180
o
F temperature.


DESIGNING HOUSING
The gearbox housing or casing serves the following functions:
y Support the bearing housings.
y Contain the lubricant
y Keep the gears in contact
The first two functions are obvious. The last one refers to the requirement of the gearbox to
resist the torque. This is either done by designing a flange-mounted gearbox or by fixing the
gearbox on the floor. The specification of the designed housing is as below:
Material : SAE/AISI 1035 hot rolled
Yield Strength : 38 kpsi
Ultimate Tensile Strength: 68 kpsi
Dimension (in) :


RESULTS
y For Gears
Location No of teeth
Torque
(lb-in)
Bending
stress (psi)
Bending
Safety
Factor
Shaft 1 (input) Gear = 82 5987.409 21524.7045 2.27

- - - -
Shaft 2
(intermediate) Gear = 82 1095.258 4457.758 10.98

Pinion = 15 1095.258 28443.359 1.72
Shaft 3
(output) - - - -

Pinion = 15 200.352 5890.626 8.31

y For Shaft
Location
Diameter of
shaft (in)
Bending
stress (psi)
Shear stress
(psi)
Fatigue Safety
factor, Nf
Static
Safety
Factor Ny
Angular
Deflection
Lateral
Deflection
(in)
Shaft 1
(input) 1.97 2721.369 3988.5 - 18.90 0.158 -0.00049
Shaft 2
(intermediate) 1.57 6752.825 1441.41 2.25 16.39 0.0135 -0.0052

Shaft 3
(output) 0.98 4047.475 1084.14 2.0 26 0.087 -0.0015


y For Key
Location
Yield Safety
Factor, N
s

Fatigue
Safety Factor
N
f
Dimension
Key 1 1.55 - 0.5 x 0.5 x 0.64

Key 2 5.07 3.2 0.375 x 0.375 x 0.64

Key 3 11.54 7.27 0.25 x 0.25 x 0.64

y For Bearing
Location Bearing No
Shaft 1 6310

Shaft 2
6308

Shaft 3 6305

The assembly of the designed part is as below:


DISCUSSION
The power transferred to the gear box is determined to be around 8.896 kW11.4 hp
based on the kinetic energy equation at 10 m/s wind velocity and 0.3 wind turbine efficiency.
The torque due to the power input will be transferred to gear box through the input shaft. The
material used for each shaft in the system is SAE/AISI 1095 (quenched & temper at 600
o
F).
From the calculation, the diameter of the shaft is 1.97 inch in order to be able to transmit
the power at 2.2 factor of safety under dynamic loading and 18.9 under static loading. At the
intermediate shaft, the diameter is 1.57 inch to transmit the power at 2.0 factor of safety under
dynamic loading and 16.9 under static loading. Lastly, at the output shaft, the diameter is 0.98
inch in order to be able to transmit the power at 2.2 factor of safety under dynamic loading and
26 under static loading.
The system is designed to utilize double stage gear train with gear ratio 30:1. The input
shaft will rotate the gear at 125 rpm (with torque equal to 5987.409 lb-in). The material used for
each gear and pinion is steel through hardened 270 HB. From the calculation, the number of
teeth for both gears and pinions are 82 and 15 respectively. Hence, the gears and pinions
diameter are 11.714 inch and 2.143 inch each. At stage 1, the factor of safety (bending) for gear
is 2.72 and 1.72 for pinion. At stage 2, factor of safety (bending) is 10.98 at gear and 8.31 at
pinion. The surface factor of safety at stage 1 is 1.213 and at stage 2 is 6.63.
In engineering application, key is a machine part to connect a rotating machine element
to a shaft. During this connection, the key will avoid a relative rotation between the two parts
and allowing torque to be transmitted. A keyway must be manufactured either on the shaft and
rotating machine for it to function.
Keys for this design are located at each gear. The keys will be used as a medium to
transfer the torque from the shaft to the gear. The input shaft key was design to get a yield factor
of safety of about 1.5, to make it the weakest link in the system. Failure to occur at this key and
if accidental overload occur it will protect the rest of the gear box.


The bearing chosen for the designed gear box is a roller type bearing element. The
selection of ball bearing for a designed shaft is based on the shaft diameter. The rolling-element
bearings have a number of advantages over sliding-contact bearings and vice versa. The
advantages of rolling elements bearing are low starting and operating friction, no self-excited
instabilities, good low temperature starting and typically require less space in axial direction.
The shaft deflection is calculated at the 3 shafts. At input shaft, the deflection is -0.00049
inch (downward), -0.0052 inch (downward) at the intermediate shaft and -0.0015 inch
(downward) at the output. The intermediate shaft shows the largest deflection because the shaft
at intermediate is the longest shaft (15 inch) compare to the other 2 shafts.

CONCLUSION
The goal of the project which is to design a prototype gear box is achieved. The designed
gear box met all the specifications required in the project. The gear ratio chosen is 30:1 which is
between the minimum ration 28:1 and maximum ration ratio 33:1. The shaft arrangement is a
double stage gear train. This arrangement was chosen to meet the specifications for the shaft
arrangement which is must be co-linear input and output shafts. The designed life of the gear box
is analysize for 10 years, continous operation. All the keys and shafts were designed for fatigue
factor of safety of 2 and yield strength factor of safety of 2.0 minimum. All the gears and
pinions was designed to get fatigue factor of safety 1.2 (surface) and 1.5 (bending) at minimum.
The drawings of all parts along with its dimension were done for fabricating purposes.


REFERENCES
1. Machine Design An Integrated Approach 3
rd
Edition, R.L. Norton
2. http://auto.howstuffworks.com/cvt1.htm
3. http://www.roymech.co.uk/Useful_Tables/Drive/Hellical_Gears.html
4. Hilbert, David; Cohn-Vossen, Stephan (1952), Geometry and the Imagination (2nd ed.),
New York: Chelsea, pp. 287, ISBN 978-0-8284-1087-8
5. M.J.T. Lewis: "Gearing in the Ancient World", Endeavour, Vol. 17, No. 3 (1993), pp.
110115 (110)


APPENDIXES

Machine-Design - Gear Shaft Problem

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MEMB 333 | Machine Design 1

(the value of is found from table 6-6)

(the value of is found from table 6-6)

(the value of is found from table 6-6)

-0.00049 inch (downward)

-0.0052 inch (downward)

-0.0015 inch (downward)

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