UNIVERSITY OF GAZİANTEP

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

308 MACHINE ELEMENT II PROJECT

GEAR DESIGN PROJECT

SUBMITTED BY:

NAME :ADEM

SURNAME :AKSOY

NUMBER :201317827

DATE:09.05.2016
 Bevel pinion Helical pinion Spur pinion

Diameter 72mm 82,3mm 99mm

Gear ratio 4 4 4,4

Module 4mm 4mm 5,5mm

Teeth 18 20 18

Face width 40mm 55mm 66,12mm

F. of safety 1,6 2 1,9

Given Datas

Diameter of conveyor drum : 18 cm

Electric motor power : 2.5 kW

Rotational speed of electric motor : 900 rpm

Linear speed of conveyor : 0,12 m/s

Gear efficiency for spur gears : 97 %

Gear efficiency for helical gears : 98 %

Gear efficiency for bevel gears : 95 %

Gear efficiency for electric motor : 90 %

Helix angle for helical gears : 15

Factor of safety : 1.5

Materials of the gears : 0808M40 HR

Reliability of the gears : 99.9 %

Min. Required life for bearings : 20 khrs

Surface hardness of spur gear sets : 38 HRC

Surface hardness of helical gear sets : 33 HRC

Surface hardness of helical gear sets : 33 HRC

Diameter of shaft 1 ( i have decided ) : 30 mm

Diameter of shaft 2 ( i have decided ) : 25 mm

Diameter of shaft 3 ( i have decided ) : 20 mm

1|S a y fa
Introduction

Gears are wheel-like machine elements that have teeth uniformly spaced
around the outer surface. Gears can be a fraction of an inch in diameter to a
hundred feet in diameter. Gears are used in pairs and are a very valuable
design tool. They are used in everything from clocks to rockets and have been
around for 3000 years. Gears are mounted on rotatable shafts and the teeth
are made to mesh (engage) with a gear on another shaft. Gears deliver force
(torque) and motion (rpm) from one part of a machine to another. Two gears
with the driven gear having twice the number of teeth of the driving gear will
rotate at one-half the speed of the driving gear and deliver twice the torque.
Being able to control speed and torque by varying the number of teeth in one
gear with respect to another makes gears a valuable design tool. An
automobile transmission is an excellent example of how this principle is put to
use to control vehicle motion.

Designing Conditions

In this project, we have a gearbox and three gear pairs in it. A bevel, a helical
and a spur pair. We will determine the all parameters. Also we have 6 bearings
at the end of the shafts. The parameters calculated on below, are written on
the table above. There are some informations to determine all dimensions and
paramters. Which are helping us to making assumptions or calculations.
General calculations are written below. Then, i will start to do calculations from
spur, helical and bevel. After it, bearing and gearbox dimensions.

2|S a y fa
Power and Gear ratio calculations.

𝑃𝑚𝑜𝑡𝑜𝑟 = 2.5 𝑘𝑊 𝑔𝑖𝑣𝑒𝑛 𝑜𝑛 𝑑𝑎𝑡𝑎𝑠ℎ𝑒𝑒𝑡

𝑃𝑚𝑜𝑡𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 = 𝑃𝑚𝑜𝑡𝑜𝑟 × 𝑒𝑓𝑓. 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 = 2.5 × 0.90 = 2250 𝑊

𝑃𝑠ℎ𝑎𝑓𝑡 3 = 𝑃𝑚𝑜𝑡𝑜𝑟 × 𝑒𝑓𝑓. 𝑜𝑓 𝑚𝑜𝑡𝑜𝑟 × 𝑒𝑓𝑓. 𝑜𝑓 𝑏𝑒𝑣𝑒𝑙 𝑝𝑎𝑖𝑟 = 2.5 × 0.90 × 0.95 = 2137 𝑊

𝑃𝑠ℎ𝑎𝑓𝑡 2 = 𝑃𝑠ℎ𝑎𝑓𝑡 1 × 𝑒𝑓𝑓. 𝑜𝑓 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑝𝑎𝑖𝑟 = 2137 × 0,98 = 2094.75 𝑊

𝑃𝑠ℎ𝑎𝑓𝑡 1 = 𝑃𝑠ℎ𝑎𝑓𝑡 2 × 𝑒𝑓𝑓. 𝑜𝑓 𝑠𝑝𝑢𝑟 𝑝𝑎𝑖𝑟 = 2094 × 0.97 = 2032 𝑊

𝑃𝑠ℎ𝑎𝑓𝑡1 𝑖𝑠 𝑎𝑙𝑠𝑜 𝑑𝑟𝑢𝑚 𝑝𝑜𝑤𝑒𝑟.

𝑣 0,12
𝜔𝑑𝑟𝑢𝑚 = = = 1.33 𝑟𝑎𝑑⁄𝑠
𝑟 (90⁄
100)
2𝜋𝑛 2 × 𝜋 × 900
𝜔𝑖𝑛𝑝𝑢𝑡 = = = 94.24 𝑟𝑎𝑑⁄𝑠
60 60
𝜔𝑖𝑛𝑝𝑢𝑡 64.24
𝐺𝑅 = = ≅ 70.6
𝜔𝑑𝑟𝑢𝑚 1.33

𝑛 𝑜𝑓 𝑠ℎ𝑎𝑓𝑡𝑠 𝑐𝑎𝑛 𝑏𝑒 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑏𝑦 𝑑𝑖𝑣𝑖𝑑𝑖𝑛𝑔 𝐺𝑅 𝑑𝑢𝑒 𝑡𝑜 𝑑𝑒𝑐𝑟𝑒𝑎𝑠𝑒

𝑛𝑚𝑜𝑡𝑜𝑟 = 900 𝑟𝑝𝑚
𝑛𝑠3 = 225 𝑟𝑝𝑚
𝑛𝑠2 = 56.25 𝑟𝑝𝑚
𝑛𝑠1 = 12.78 𝑟𝑝𝑚

𝑅𝑎𝑡𝑖𝑜 𝑑𝑖𝑠𝑡𝑟𝑖𝑏𝑢𝑡𝑖𝑜𝑛 𝑖𝑠 4 − 4 − 4.4 𝑒𝑞𝑢𝑎𝑙𝑠 𝑡𝑜 70.4 𝑖𝑠 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒.

𝑀𝑎𝑡𝑒𝑟𝑖𝑎𝑙 𝑖𝑠 0808𝑀40 𝐻𝑅 𝑆𝑡𝑒𝑒𝑙 ℎ𝑎𝑠 550 𝑀𝑃𝑎 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔ℎ𝑡.

3|S a y fa
Calculation of Spur gear

𝑇𝑝 = 18, 𝑚 = 5.5𝑚𝑚, 𝐺𝑅 = 4.4 𝑎𝑠𝑠𝑢𝑚𝑒𝑑.

𝑑𝑝 = 𝑚𝑇𝑝 = 99𝑚𝑚

𝑑𝑔 = 𝑚𝑇𝑔 𝑇𝑔 = 𝐺𝑅 × 𝑇𝑝 ≅ 79 𝑑𝑔 = 434.5
99
𝜋𝑑𝑛 𝜋 × (1000) × 56.25
𝑣𝑝 = = = 0.29 𝑚⁄𝑠
60 60
𝑃 2094.75
𝑊𝑡 = = = 7223 𝑁
𝑉 0.29
Surface durability

𝑊𝑡𝑝
𝑆𝐻 = 𝐶𝑝 √
𝐹𝐼𝑑𝐶𝑣
𝑊𝑡𝑝
𝐹=
𝑆 2
(𝐶𝐻 ) 𝐼𝑑𝐶𝑣
𝑝
𝑊𝑡𝑝 = 𝑛 × 𝐶𝑂 × 𝐶𝑀 × 𝑊𝑡 𝐶𝑂 = 1(𝑢𝑛𝑖𝑓𝑜𝑟𝑚, 𝑢𝑛𝑖𝑓𝑜𝑟𝑚) 𝐶𝑀 = 1.5(𝐹 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 50 − 150)
𝐶𝐿 𝐶𝐻
𝑆𝐻 = 𝑆 ≫ 𝑆𝐶 = 2.76𝐻𝐵 − 70 38𝐻𝑅𝐶 = 348𝐻𝐵
𝐶𝑅 𝐶𝑇 𝐶
𝐶𝐿 = 1 > 𝑙𝑖𝑓𝑒 108
𝐶𝑅 = 1 > 𝑅 = 99.9
𝐶𝑇 = 1 > 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝐶𝐻 = 1 > 𝑓𝑜𝑟 𝑠𝑝𝑢𝑟 𝑔𝑒𝑎𝑟𝑠
𝑆𝐻 = 890.48 𝑀𝑃𝑎
𝐶𝑃 = 191 √𝑀𝑃𝑎
𝑐𝑜𝑠∅𝑠𝑖𝑛∅ 𝑚𝐺 𝑐𝑜𝑠20𝑠𝑖𝑛20 4.4
𝐼= ( )= ( ) = 0,1309
2 𝑚𝐺 + 1 2 4.4 + 1
50
𝐶𝑣 = = 0.862 ℎ𝑜𝑏𝑏𝑒𝑑 𝑜𝑟 𝑠ℎ𝑎𝑝𝑒𝑑
50 + √200𝑣
16251
𝐹= 2
890,5
( ) × 0,1309 × 99 × 0,862
191

𝐹 = 66.12 𝑚𝑚
3𝑃𝐶 ≤ 𝐹 ≤ 5𝑃𝐶 𝑃𝐶 = 𝜋𝑚 = 17.27 𝑚𝑚 𝑭 𝒊𝒔 𝑶𝑲‼!

4|S a y fa
Bending Fatigue Failure
𝑊𝑡
𝜎=
𝐹𝑚𝐽𝐶𝑣
𝐽 = 0,349 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒. 𝐴𝑛𝑑 𝑡ℎ𝑒 𝑜𝑡ℎ𝑒𝑟 𝑡𝑒𝑟𝑚𝑠 ℎ𝑎𝑣𝑒 𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 𝑏𝑒𝑓𝑜𝑟𝑒.
𝜎 = 65 𝑀𝑃𝑎
𝑆𝑒 = 𝑘𝑎 × 𝑘𝑏 × 𝑘𝑐 × 𝑘𝑑 × 𝑘𝑒 × 𝑆𝑒′

𝑆𝑒′ = 𝑆𝑢 × 0.5 = 550 × 0.5 𝑑𝑢𝑒 𝑡𝑜 𝑆𝑢 < 1400 𝑀𝑃𝑎 𝑓

𝑆𝑒′ = 275 𝑀𝑃𝑎

𝑘𝑎 = 0,76 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑏 = 0,902 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑐 = 0.753 reliability is 99,9%

𝑘𝑑 = 1 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝑘𝑓 = 1.33

𝑆𝑒 = 188.8 𝑀𝑃𝑎
𝑆𝑒 188,8
𝑛𝐺 = = = 2.9
𝜎 65
𝑛𝐺
𝑛= = 1.9 𝑂𝐾‼!
𝐶𝑂 𝐶𝑚
Controlling Contact Ratio

2 − 𝑟2 + 𝑟2 − 𝑟2 ) − ( 𝑟2 − 𝑟2 + 𝑟2 − 𝑟2 )
(√𝑟𝑎𝑝
𝐿 𝑏𝑝 √ 𝑎𝑔 𝑏𝑔 √𝑔 𝑏𝑔 √𝑝 𝑏𝑝
𝐶𝑟 = =
𝑃𝑏 𝑃𝑐 cos ∅
𝑎=𝑚 𝑏 = 1.25𝑚 𝑟𝑏𝑝 = 𝑟𝑝 cos ∅ 𝑟𝑏𝑔 = 𝑟𝑔 cos ∅
(√552 − 46,482 + √223,32 − 204,52 ) − (√217,82 − 204,52 + √49,52 − 46,472 )
𝐶𝑟 =
5,5 × 𝜋 cos 20
𝐶𝑟 = 6,16 ≫ 1,6 𝑂𝐾‼!

Forces on gears

𝑭𝒐𝒓 𝒑𝒊𝒏𝒊𝒐𝒏 𝑊𝑡 = 7184 𝑁 𝑊𝑟 = 𝑊𝑡 𝑡𝑎𝑛20 = 2614 𝑁

𝑆𝑎𝑚𝑒 𝑓𝑜𝑟𝑐𝑒𝑠 𝑤𝑖𝑙𝑙 𝑎𝑐𝑡 𝑜𝑛 𝑔𝑒𝑎𝑟

5|S a y fa
Calculations of Helical Pair
𝑇𝑝 = 20 𝑎𝑠𝑠𝑢𝑚𝑒𝑑 𝑇𝑔 = 20 × 4 = 80 𝑚 = 4 𝑎𝑠𝑠𝑢𝑚𝑒𝑑
𝑚𝑡 = 𝑚 × cos 𝜑 = 4 × cos 15 = 4.14𝑚𝑚
𝑑𝑝 = 𝑇𝑝 × 𝑚𝑡 ≅ 82.3𝑚𝑚 𝑑𝑔 = 𝑇𝑔 × 𝑚𝑡 ≅ 298𝑚𝑚
𝑝𝑛 = 𝑚 × 𝜋 = 12,56𝑚𝑚 𝑝𝑡 = 𝑚𝑡 × 𝜋 = 13𝑚𝑚
𝑝𝑡
𝑝𝑥 = = 48.5𝑚𝑚
𝑡𝑎𝑛 𝛹
𝜋𝑑𝑛 𝑚
𝑉𝑝 = = 0,975
60 𝑠
Surface Durability

𝑃 2137.5
𝑊𝑡 = = = 2192 𝑁
𝑉 0,975
𝑊𝑡𝑝
𝐹=
𝑆 2
(𝐶𝐻 ) 𝐼𝑑𝐶𝑣
𝑝
𝑊𝑡𝑝 = 𝑛 × 𝐶𝑂 × 𝐶𝑀 × 𝑊𝑡 𝐶𝑂 = 2(𝑙𝑖𝑔ℎ𝑡, ℎ𝑒𝑎𝑣𝑦 𝑠ℎ𝑜𝑐𝑘) 𝐶𝑀 = 2.25(𝑓𝑢𝑙𝑙 − 𝑓𝑎𝑐𝑒 𝑐𝑜𝑛𝑡𝑎𝑐𝑡 )
𝐶𝐿 𝐶𝐻
𝑆𝐻 = 𝑆 ≫ 𝑆𝐶 = 2.76𝐻𝐵 − 70 33𝐻𝑅𝐶 = 308𝐻𝐵
𝐶𝑅 𝐶𝑇 𝐶
𝐶𝐿 = 1 > 𝑙𝑖𝑓𝑒 108
𝐶𝑅 = 1 > 𝑅 = 99.9
𝐶𝑇 = 1 > 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝐶𝐻 = 1 > (𝐾 < 1.2)
𝑆𝐻 = 780 𝑀𝑃𝑎
𝐶𝑃 = 191 √𝑀𝑃𝑎

78 𝑃𝑛 cos ∅𝑛
𝐶𝑣 = √ = 0.99 𝑚𝑁 = = 0.65
78 + √200𝑣 0,95𝑍

tan ∅ tan 20
∅𝑡 = tan−1 ( ) = tan−1 ( ) = 20.6
cos Ψ cos 15

1 
2
r
 a   rbp  rp  d p / 2  41,15 
p
2
1  23,6
 r  d / 2  149 
Z 1  2  3  2  g  a 2
r
 rbg
2


g g 

2  63
3  rp  rg * sin t  rbp  rp * cos t  38.5  3  67

rbg  rg * cos t  139.5
 Z  19
am4
𝑐𝑜𝑠∅𝑡 𝑠𝑖𝑛∅𝑡 𝑚𝐺
𝐼= ( ) = 0,2
2𝑚𝑁 𝑚𝐺 + 1
𝑊𝑡𝑝
𝐹= = 54.4 → 55𝑚𝑚
𝑆 2
(𝐶𝐻 ) 𝐼𝑑𝐶𝑣
𝑝

6|S a y fa
Checking for bending failure
𝑊𝑡
𝜎𝑏 = 𝐽 = 𝐽 × 𝑚𝑢𝑙𝑡𝑖𝑝𝑙𝑖𝑒𝑟 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒. 𝐽 = 0,51 × 0,93 = 0,47
𝐹𝐽𝑚𝑡 𝐶𝑣
𝜎𝑏 = 20.7 𝑀𝑃𝑎
𝑆𝑒 = 𝑘𝑎 × 𝑘𝑏 × 𝑘𝑐 × 𝑘𝑑 × 𝑘𝑒 × 𝑆𝑒′

𝑆𝑒′ = 𝑆𝑢 × 0.5 = 550 × 0.5 𝑑𝑢𝑒 𝑡𝑜 𝑆𝑢 < 1400 𝑀𝑃𝑎 𝑓

𝑆𝑒′ = 275 𝑀𝑃𝑎

𝑘𝑎 = 0,76 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑏 = 0,93 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑐 = 0.753 reliability is 99,9%

𝑘𝑑 = 1 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝑘𝑓 = 1.33

𝑆𝑒 = 194.6 𝑀𝑃𝑎
𝑆𝑒 194.6
𝑛𝐺 = = = 9.4
𝜎 20.7
𝑛𝐺
𝑛= =2 𝑂𝐾‼!
𝐶𝑂 𝐶𝑚
Contact ratio
𝑍 𝐹 19 55
𝑐𝑟 = 𝑝𝑐𝑟 + 𝑎𝑐𝑟 = ( )+( )=( )+( ) = (1,57) + (1,13) = 2.7
𝑃𝑏𝑡 𝑃𝑥 𝜋𝑚𝑡 cos ∅𝑡 48.5
Forces on the gear and pinion
𝑊𝑡
𝑓𝑜𝑟 𝑝𝑖𝑛𝑖𝑜𝑛 𝑊𝑡 = 2192𝑁 𝑊= = 2424𝑁
cos ∅𝑛 cos Ψ

𝑊𝑎 = 𝑊 × cos ∅𝑛 sin Ψ = 583𝑁 𝑊𝑟 = 𝑊 × sin ∅𝑡 = 853 𝑁

Also, same forces will act on gear, due to reaction.

7|S a y fa
Calculations of Bevel Pair
𝑇𝑝 = 18, 𝑚 = 4𝑚𝑚, 𝐺𝑅 = 4 𝑎𝑠𝑠𝑢𝑚𝑒𝑑.

𝑑𝑝 = 𝑚𝑇𝑝 = 72𝑚𝑚

𝑑𝑔 = 𝑚𝑇𝑔 𝑇𝑔 = 𝐺𝑅 × 𝑇𝑝 ≅ 72 𝑑𝑔 = 288
𝜋𝑑𝑎𝑣𝑒 𝑛
𝑣𝑝 =
60
𝑇𝑝
𝛾 = tan−1 ( ) = 14
𝑇𝑔
𝐴𝑜
𝑑𝑎𝑣𝑒 = d − Fsinγ F= or F = 10m which is smaller.
3
2
𝑑𝑝 2 𝑑𝑔
𝐴𝑜 = √( ) + ( ) ≅ 148.5 mm F = 40mm
2 2
𝑑𝑎𝑣𝑒 = 62.3 mm
𝑣𝑝 = 2,93 m/s
𝑃 2250
𝑊𝑡 = = = 768 𝑁
𝑉 2,93

Surface durability
2
𝑆𝐻
𝑊𝑡𝑝 = ( ) × 𝑑𝑝 × 𝐶𝑣 × 𝐼 × 𝐹
𝐶𝑝
𝐶𝐿 𝐶𝐻
𝑆𝐻 = 𝑆 ≫ 𝑆𝐶 = 2.76𝐻𝐵 − 70 33𝐻𝑅𝐶 = 308𝐻𝐵
𝐶𝑅 𝐶𝑇 𝐶
𝐶𝐿 = 1 > 𝑙𝑖𝑓𝑒 108
𝐶𝑅 = 1 > 𝑅 = 99.9
𝐶𝑇 = 1 > 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝐶𝐻 = 1 > 𝑓𝑜𝑟 𝑠𝑝𝑢𝑟 𝑔𝑒𝑎𝑟𝑠
𝑆𝐻 = 890.48 𝑀𝑃𝑎
𝐶𝑃 = 232.5 √𝑀𝑃𝑎
𝐼 = 0,072 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒
50
𝐶𝑣 = = 0,67
50 + √200𝑣
𝑊𝑡𝑝 = 1564 𝑁
𝑊𝑡𝑝 1564 𝑛𝐺
𝑛𝐺 = = =2 𝑛= = 1.6 𝑂𝐾‼!
𝑊𝑡 768 𝐶𝑜 × 𝐶𝑚
𝐶𝑜 = 1 (𝑢𝑛𝑖𝑓𝑜𝑟𝑚, 𝑢𝑛𝑖𝑓𝑜𝑟𝑢𝑚)
𝐶𝑚 = 1,25 (𝑜𝑛𝑒 𝑖𝑠 𝑖𝑛𝑏𝑜𝑎𝑟𝑑, 𝑜𝑛𝑒 𝑖𝑠 𝑜𝑢𝑡𝑏𝑜𝑎𝑟𝑑)

8|S a y fa
Bending Failure
𝑊𝑡
𝜎= 𝐽 = 0,376 𝑓𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒
𝐶𝑣 × 𝐹 × 𝑚 × 𝐽
𝜎 = 19 𝑀𝑃𝑎
𝑆𝑒 = 𝑘𝑎 × 𝑘𝑏 × 𝑘𝑐 × 𝑘𝑑 × 𝑘𝑒 × 𝑆𝑒′

𝑆𝑒′ = 𝑆𝑢 × 0.5 = 550 × 0.5 𝑑𝑢𝑒 𝑡𝑜 𝑆𝑢 < 1400 𝑀𝑃𝑎 𝑓

𝑆𝑒′ = 275 𝑀𝑃𝑎

𝑘𝑎 = 0,76 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑏 = 0,93 𝐹𝑟𝑜𝑚 𝑡𝑎𝑏𝑙𝑒

𝑘𝑐 = 0.753 reliability is 99,9%

𝑘𝑑 = 1 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

𝑘𝑓 = 1.33

𝑆𝑒 = 194.6 𝑀𝑃𝑎
𝑆𝑒 194.6
𝑛𝐺 = = = 10
𝜎 19
𝑛𝐺
𝑛= =8 𝑂𝐾‼!
𝐶𝑂 𝐶𝑚

Forces on gears
𝑊𝑡
𝑊𝑡 = 768 𝑁 𝑊= = 817 𝑁
𝑐𝑜𝑠∅
𝑊𝑟 = 𝑊𝑡 tan ∅ cos 𝛾 = 271 𝑁 𝑊𝑎 = 𝑊𝑡 𝑡𝑎𝑛∅𝑠𝑖𝑛𝛾 = 67 𝑁
𝑆𝑎𝑚𝑒 𝑙𝑜𝑎𝑑𝑠 𝑎𝑡 𝑔𝑒𝑎𝑟.

9|S a y fa
Bearing Selections
We have six bearings totaly. On shaft 1, there is no axial forces. But shaft 2 and shaft 3, there
will be axial loading. On shaft 3, axial force has two component. Due to bevel gear and due
to helical gear. If directio will be same. The maximum stress will occur. And calculated fort
his condition. All results written in positive sign. Direction is not important on bearings.

𝑊𝑎 = 𝑊 × cos ∅𝑛 sin Ψ = 583𝑁 𝑊𝑟 = 𝑊 × sin ∅𝑡 = 853 𝑁

Shaft 1

𝑊𝑆1 = √𝑊𝑟2 + 𝑊𝑡2 = 7645 𝑁

∑ 𝑀𝑎 = 0 →→ 𝑊𝑡 × 0,45 − 𝑅𝑏 × 0,65 = 0 𝑅𝑏 = 5293 𝑁

∑ 𝐹 = 0 →→ 7184 − 5293 − 𝑅𝑎 = 0 𝑅𝑎 = 1891 𝑁

Shaft 2

𝑊𝑆2 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 = √𝑊𝑟2 + 𝑊𝑡2 = 2352 𝑁

∑ 𝑀𝑑 = 0 →→ 𝑊ℎ𝑒𝑙𝑖𝑐𝑎𝑙 × 0,4 − 𝑊𝑠𝑝𝑢𝑟 × 0,2 − 𝑅𝑐 × 0,65 = 0 𝑅𝑐 = 905 𝑁

∑ 𝑊𝑎 = 583 𝑁

Shaft 3

𝑊𝑆2 𝑏𝑒𝑣𝑒𝑙 = √𝑊𝑟2 + 𝑊𝑡2 = 815 𝑁

∑ 𝑀𝑓 = 0 →→ 𝑊𝑏𝑒𝑣𝑒𝑙 × 0,65 − 𝑊ℎ𝑒𝑙𝑖𝑐𝑎𝑙 × 0,4 − 𝑅𝑒 × 0,85 = 0 𝑅𝑒 = 493 𝑁

∑ 𝑊𝑎 = 𝑊𝑎 𝑏𝑒𝑣𝑒𝑙 + 𝑊𝑎 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 = 650 𝑁

10 | S a y f a
 3
 C   16667 
L  *   20khrs FegvA  V * AF * FeA
F   n 
 egvA   rpm 
V and AF values are equals to 1. If there will be any change, shows in selection part. All bearings are
roller contact bearing. And selected from SKF table.

Bearing A (carries just direct loading)

𝐹 = 1891 𝑁 𝑛 = 225 𝐶 = 6650 𝐿 ≅ 58𝑘ℎ𝑟𝑠

SKF-16006
Bearing B (carries just direct loading)

𝐹 = 5293 𝑁 𝑛 = 225 𝐶 = 15000 𝐿 ≅ 30.3 𝑘ℎ𝑟𝑠

SKF-6208
Bearing C (carries just direct loading)

𝐹 = 905 𝑁 𝑛 = 56.25 𝐶 = 5850 𝐿 ≅ 80 𝑘ℎ𝑟𝑠

SKF-16005
Bearing D (carries just axial loading)

𝐹 = 583 𝑁 𝑛 = 56,25 𝐶 = 5850 𝐿 ≅ 300 𝑘ℎ𝑟𝑠

SKF-16005
Bearing E (carries just direct loading)

𝐹 = 493 𝑁 𝑛 = 12.5 𝐶 = 5400 𝐿 ≅ 97 𝑘ℎ𝑟𝑠

SKF-16004
Bearing F (carries just axial loading)

𝐹 = 650 𝑁 𝑛 = 12.5 𝐶 = 5400 𝐿 ≅ 42.5 𝑘ℎ𝑟𝑠

SKF-16004

All bearings are higher than 20khrs. And that is OK.

11 | S a y f a
Dimensions of gearbox
For gearbox, we have some constrains. First, depth of gearbox must be higher than the
highest gear.
Another is that, if there is not enough distance between C bearing and bevel gear, that will
be out of sense. This is also same as distances between shafts.So, calculations are below.

𝐵𝑒𝑎𝑟𝑖𝑛𝑔 𝐶 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 42𝑚𝑚

𝐵𝑒𝑣𝑒𝑙 𝑔𝑒𝑎𝑟 𝑟𝑎𝑑𝑖𝑢𝑠 = 144𝑚𝑚
42 + 144 = 186 𝑎𝑛𝑑 ℎ𝑒𝑙𝑖𝑐𝑎𝑙 𝑝𝑖𝑛𝑖𝑜𝑛 𝑟𝑎𝑑𝑖 𝑖𝑠 41.15 𝑔𝑒𝑎𝑟 𝑟𝑎𝑑𝑖 𝑖𝑠 149𝑚𝑚
41.15 + 149 = 190.15 𝑎𝑛𝑑 𝑡ℎ𝑒𝑟𝑒 𝑤𝑖𝑙𝑙 𝑏𝑒 4𝑚𝑚 𝑑𝑖𝑠𝑡𝑎𝑛𝑐𝑒. 𝑡ℎ𝑖𝑠 𝑤𝑖𝑙𝑙 𝑏𝑒 𝑂𝐾!

𝑟𝑠𝑝 + 𝑟𝑠𝑔 + 𝑟ℎ𝑝 + 𝑟ℎ𝑔 + 𝑟𝑏𝑔 = 640𝑚𝑚

𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛 60𝑚𝑚 𝑓𝑜𝑟 𝑚𝑜𝑡𝑜𝑟 𝑠ℎ𝑎𝑓𝑡 60𝑚𝑚

𝐷𝑒𝑝𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟𝑏𝑜𝑥 > 298𝑚𝑚 𝑤ℎ𝑖𝑐ℎ 𝑤𝑖𝑙𝑙 𝑏𝑒 310𝑚𝑚 𝑖𝑠 𝑖𝑑𝑒𝑎𝑙.

𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟𝑏𝑜𝑥 𝑖𝑠 𝑔𝑖𝑣𝑒𝑛 𝑜𝑛 𝑞𝑢𝑒𝑠𝑡𝑖𝑜𝑛 𝑖𝑠 850𝑚𝑚.
𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑔𝑒𝑎𝑟𝑏𝑜𝑥 > 700𝑚𝑚 𝑎𝑙𝑠𝑜 700𝑚𝑚 𝑖𝑠 𝑖𝑑𝑒𝑎𝑙

𝟕𝟎𝟎𝒎𝒎 × 𝟖𝟓𝟎𝒎𝒎 × 𝟑𝟏𝟎𝒎𝒎

Conclusion

In this Project, i have determined the stress values and dimensions of gears. At input stage
we had a torque and desired output was conveyor motion. A gearbox is using for this kind of
operation and called as reductor. Gearbox dimensions are enough fort his system. And its
production is not complicated. But in the Project, some of gears dimensions are a little bit
complicated. Most of the values are rolled up or down. But some of them not rolled up. The
tables, specific values and equations have taken from Shigley’s first edition book. All
bearings are selected from SKF table ( deep Groove ball bearing).

12 | S a y f a