Gearbox Design (Layout only)

Gearbox Design Issues:

1. Shafts
2. Rotating Elements
(i.e., gears, sprockets, pulleys, etc.)
3. Bearings
4. Securing elements
5. Seals
6. Housing layout
 Shafts: Functions

Locate and secure components in

an appropriate manner and in their
proper position.
Transmit all applied forces to their respective
reaction point in the most efficient way.
Shaft Components To Consider
Shaft Components To Consider
Internal Components, such as, gears.
Shaft Components To Consider
Output Devices: Pulleys, Sprockets, Sheaves, etc.
Shaft Components To Consider
Bearings: ball, roller, sliding.

For more about seals, visit www.skf.com

Methods of Securing Components

1. Welding
Permanent assemblies
2. Machining from the solid shaft Not intended for
3. Interference or transitional fits replacement
4. Locating pins or dowels pins
5. Spacers and Sleeves
6. Keyways and keys
7. Splined Shafts
8. Steps and shoulders
9. Threaded fasteners
10. Clamping rings, collars, end caps
11. Friction fits (Taper Lock)
Secure the Components Circumferentially
Splines
External splines

Internal splines
Secure the Components Circumferentially
Keys, pins, set screws, etc.

Pin hole in the shaft

Key

Pin
Pin hole in the hub
Secure bearing Circumferentially
by press-fit Inner ring press fit to the shaft

Outer ring press fit to the housing

Secure the Components Axially by
Shoulders, Snap rings (or retaining rings)

Secured by the snap rings

Secure the Components Axially by
nuts
Bearing Lock Nut:
Couplings

- flexible couplings allow axial,

radial, and angular misalignments
- easy assembly and disassembly

For more information, please visit: www.ktr.com

 Seals Seals: labyrinth, O-rings, lips, etc.

For more info. about seals, visit www.trisunltd.com

Gearbox forces to be considered
1. Tangential Drive Force on Gear Teeth, Ft
(torque transmitted to do work)
Ft
Torsion on shaft.

F
Fa
Fr
Gearbox forces to be considered
2. Axial Force Due to Helix Angle, Fr
(not to do work)
-Axial tension/compression on shaft.
-Cyclical bending moment on shaft.
Ft

Fa
Fr
Gearbox forces to be considered
3. Radial Force on Gear Tooth, Fr
(not do work)
-Cyclical bending force on shaft.

Ft

Fa
Fr
Gearbox forces to be considered
4. Weight of the Gear and Shaft

-Radial Bearing reactions.

Gearbox forces to be considered
5. Externally Applied Loads

-Overhung bending moment

-Axial Thrust Load on the shaft.

Overhung Bending
due to belt or chain
tension

Axial Thrust
Detailed Shaft Design Features
Bearing Seats and Housings: Corner Details
 General issues to be considered
1. What is the purpose of each device?

2. What must NOT occur (slippage of gear on shaft, )?

3. Which parts must be fixed & which parts must be

allowed to move?

4. What is the sequence of assembly?

5. What can fail and how will it happen?

6. How is the unit disassembled for repair?

7. What are maintenance requirements?

Detailed Shaft Design Features
Keyways
Steps & Shoulders
Fillets and Chamfers
Notches and Grooves
Thread Details
Bearing Seats and Housings
Gear Mounting Techniques
Spacers and Sleeves
 Common practice in Shaft Design
Shafts get larger as speeds are reduced
Small pinions are often machined onto shafts
Larger gears generally use keys to transmit torque to shafts
Steps, Spacers and Retaining Rings are common ways to
locate gears
Use Shims for adjustment and fine alignment of parts
Bearing Locking Nuts are a good way to secure Bearings
Consider stress risers due to grooves and sharp steps in
shafts
Use chamfers to ease assembly and avoid interferences