Design of Gear Boxes for

Machine tool
Introduction
 Gear Box :
 Mechanical device –transmitting power from prime mover to machine
with:
 (i) Change in torque & speed or/and
 (ii) Change in orientation of drive

 Purpose of using Gear Box:

 torque
 Standard speed of prime mover
Specific speed of a drive machine
 Single i/p speed multiple o/p speeds
 Facilitate specific relative position of machine shaft & prime mover
shaft
 speed
 Types of Gear Boxes
GEAR BOXES

 Non – intersecting
 Intersecting & perpendicular
 Parallel Axes  Co- Axial Axes Axes

 Single  Multi stage

stage

 Single  Multi
speed speed

Constant Sliding Synchromesh

Mesh Mesh
Need of multi speed gear box
 In m/c tool different operation requires different spindle
speeds. Dn
 Cutting speed v  m/min
1000
 Therefore 1000v
n
D
 Even for one machining operation required spindle speed is
different for different w/p diameter
 But available speed (motor) is single
 So for obtaining no.of o/p speeds for single i/p speed MULTI-
SPEED gear box is required in m/c tool.
Basic considerations in the design of
multi-speed drives
 10 t0 15 % speed increment range
 Non-stop operation while changing speeds(more speed ratios
needed)
 Any speed to any speed possible directly
 No auxiliary arrangements or countershafts. Axial length- least
– cluster gear(Sliding)- not more than 3 gears.(Compact)
 Only regulating gears to be engaged. Minimum number of
components.
 Centralized control designed ergonomically
Determination of Variable speed
range:
 Ideal speed range in m/c tool –
infinite no.of speed ratios
 Allows optimum operation of m/c for any job diameter.
 Such speed regulation called “stepless regulation “
 From cost and utility perspective optimum gear ratios
should be available to get different speed ranges bet max.
and min. speed.
 These intermediate speed obtained by different laws.
 a) Arithmetic Progression (AP)
 b) Geometric Progression (GP)
 c) Harmonic Progression (HP)
Arithmetic Progression (AP)
 Difference between 2 adjacent rpm value is constant
 Various intermediate speed:
N1  N min
N 2  N1  a  N min  a
N 3  N 2  2a  N min  2a
N K  N K 1  a  N min  (k  1)a
N K 1  N K  a  N min  Ka
N Z  N Z 1  a  N min  ( Z  1)a  N max
N max  N min
a
Z 1
Arithmetic Progression (AP)
 Considering any 2 intermediate speed range NK and NK+1
corresponding diameters machined would be:
1000v
D 
K N
K
1000v
DK 1 
N K 1

 Range of diameters,
DK  DK  DK 1
1000v  1 1 
DK  
  N K N K 1 

 Arithmetic Progression (AP)
 Consider a multi-speed gear box with following specification
 Minimum speed = 30 rpm
 Maximum speed = 385 rpm
 No.of speed = 12
 Cutting speed = 20 m/min, calculate all parameters
 Find a Sr. N (rpm) GEAR RATIO Ф = D ΔDK
k K
No  N K 1 

 N 

 K 

1 30 (62.273/30) = 2.08 212.21 109.98

2 30+32.273=62.273 (94.546/62.273) = 1.52 102.23 34.90
11 320.457+32.273=352.73 (385/352.730)=1.09 18.05 1.51
12 352.730+32.23=385 ….. 16.54 ……

 With AP at low rpm more speed range desired than available

 At high rpm some of speed range are not necessary
Geometric Progression (GP)
 Gear ratio b/w 2 consecutive speed ranges remain the same
(ratio of any 2 successive spindle speed is constant)
N1  N min
N 2  N1  N min
N 3  N 2  N min 2
N K  N K 1  N min ( k 1)
N K 1  N K   N min k
N Z  N Z 1  N min ( z 1)  N max
1
 N K 1   N max  z 1
      
 N K   N min 
 Geometric Progression (GP)
 Consider a multi-speed gear box with following specification
 Minimum speed = 30 rpm
 Maximum speed = 385 rpm
 No. of speed = 12
 Cutting speed = 20 m/min, calculate all parameters
Sr. N (rpm) GEAR RATIO Фk= DK ΔDK
No  N K 1 

 N 

 K 

1 30 1.26 212.21 43.92

2 30X 1.261=37.830 1.26 168.28 34.83
11 241.856X1.261=304.981 1.26 20.87 4.32
12 304.981X1.261=385 ….. 16.55 ……

 With GP at low rpm more speed range desired than available

 At high rpm some of speed range are not necessary
Harmonic Progression (HP)
 Diameter change between 2 consecutive speed ranges remain
same (Difference b/w reciprocal of any 2 successive spindle
speed is constant)
 As diameter ratio remains constant, we get:
1000v  1 1 
DK      Cons tan t
  N K N K 1 

 Reciprocal of any 2 successive spindle speed is constant

1 1
 C
N K N K 1

 NK 
N K 1   
 1  CN K 
Harmonic Progression (HP)
N K 1
 Ratio of successive speed K 
NK
N1  N min or
 1 
N1 K   
N2  1  CN K 
1  CN1
 N1 
 
N2  1  CN1  N1
N3   
1  CN 2  CN1  1  2CN1
1  
 1  CN1 
Harmonic Progression (HP)
N K 1 N1 N min
NK   
1  CN K 1 1  ( K  1)CN1 1  ( K  1)CN min

NK N1
N K 1  
1  CN K 1  KCN1
.
.
. N Z 1 N1 N min
NZ     N max
1  CN Z 1 1  ( Z  1)CN1 1  ( Z  1)CN min
Harmonic Progression (HP)
N min
1  ( Z  1)CN min 
N max

N max  N min
C
( Z  1) N max N min

 N K 1  1
K   
 N K  1  CN K
 Harmonic Progression (HP)
 Consider a multi-speed gear box with following specification
 Minimum speed = 30 rpm, Maximum speed = 385 rpm
 No. of speed = 12
 Cutting speed = 20 m/min, calculate all parameters, Find C
Sr. N K 1 GEAR RATIO Фk= DK ΔDK
No NK  N 
1  CN K 1 
 N 
K 1

 K 

1 30 (3.25/30)=1.091 212.21 17.79

2 30/(1-2.794X10-3X30) (36.043/32.745)=1.01 194.42 17.79
=32.745
11 122.163/(1-2.794X10-3 (385/185.474)=2.076 34.32 17.79
X122.163) =185.474
12 185.474/(1-2.794X10-3 ….. 16.54 ……
X184.474) =385

 Better distribution of speeds in lower speed range

 For higher speeds huge speed difference – un economical m/cing
Comparison of Different
progression in Gear Box Design
AP GP HP
Constant change in Constant Gear Ratio at Constant diameter
speed at every stage every stage change at every stage
Low speed zone Low speed zone , better High speed zone
requires much more than AP, but still needs a requires much more
steps for optimised few more steps for steps for optimised
machining optimised machining machining

Not based on preferred Based on a preferred Not based on a

number of series number of series preferred number of
series

AP is very inefficient in low speed ranges

HP is very inefficient in high speed ranges
DUE TO THIS GP IS PREFERRED
Advantages of Geometric Progression

 Constant loss of Economic cutting speed in the

whole rpm range
K  1
 max  Vopt
 K  1

 Better Gear Box design

 In any geometric progression other than GP all speeds
obtained from a simple gear train arrangement.
 In GP – Compound gear train arrangement (reduces gear
pair)
Selection of geometric progression
ratio (φ) in multi speed gear box:
N max N Z NZ N N N
   Z 1  ......  3  2
N min N1 N Z  1 N Z 2 N 2 N1

  . ..... . ( Z  1)times 
N max
  ( Z 1 )
N min
1
 N max  ( Z 1 )
 
N
 min 

1
  RN ( Z 1 )
Selection of geometric progression
ratio (φ) in multi speed gear box:
 Maximum loss of economic cutting speed[(Δv)max]:
K  1 
 We know that ( v )max  Vopt
K  1 

 Max. percentage loss of economic cutting speed

( v )max   1 
 100     100
v opt   1 
Selection of geometric progression
ratio (φ) in multi speed gear box:

 Effect of lower φ:

K  1  1
( v )max  Vopt
K  1    RN ( Z 1)

 Effect of Higher φ:
Selection of geometric progression
ratio (φ) in multi speed gear box:
 Standard values of φ:
 To compromise between
 Loss of economic cutting speed & compactness of drive
 Φ selected such that 1    2
20  R  20 10  1.12
 Standard value of φ are based on 10  R  10 10  1.26
 Series of Preferred Numbers 20  R 
20 3
10  1.41
3

5  R  5 10  1.58
4  R  4 10  1.78
10
10  R  3
10  2.0
3
 Selection of geometric progression
ratio (φ) in multi speed gear box:
φ 1.06 1.12 1.26 1.41 1.58 1.78 2.0
% Loss of
economic 2.9 5.7 11.5 17.0 22.5 28.1 33.3
cutting speed

  1 
   1   100
Compactness Increases
Increases
 
of Drive

Smaller Ф (1.06,1.12,1.26) – Heavy duty machine tools and automats

Larger Ф (1.58, 1.78,2.0) – Small sized special purpose m/c tool

Selection of geometric progression
ratio (φ) in multi speed gear box:
 Recommended values of φ in machine tool:

Machine Tool Recommended value of φ

Heavy duty machine tools and automats 1.12
Large to medium size, general purpose 1.26
machine tools and automats
Medium size, general purpose machine tools 1.41
Medium to small size , general purpose 1.58
machine tools
 Selection of geometric progression
ratio (φ) in multi speed gear box:
 Φ with two speed motors:
 Ratio of two speed is generally = 2 (eg. 750 rpm and 1500rpm)
 Φ must satisfy the following conditions:
 (i). Motor speed lower rpm Higher rpm

 New spindle speed series should match existing spindle speed series
(Any spindle speed ‘NK’ must double after certain no.of speed steps
‘S1’ S
N K .  2N K   2
1 1
 S1


S2
(ii).Φmust
 be10according   1
 to Preferred
10 S 2 series
 Selection of geometric progression
ratio (φ) in multi speed gear box:
Φ with two speed motors:
1 1
log 10 2  log10 2
  2   10
1 1 S1 S2
S1 S2
S2 1
 
S1 = No. of steps reqd. for making spindle S1 log 10 2
speed twice 10
S2 = Preferred series number(5,10, 20, etc,) S2  S1
3

S1 1 2 3 6 12
S2 10/3 20/3 10 20 40
Preferred R 10/3 R 20/3 R 10 R 20 R 40
series
φ 2.0 1.41 1.26 1.12 1.06
Preliminary steps in the Design of
Multi stage Gear Box
 1.Selection of a Range ratio:
 Range ratio: ratio of maximum spindle speed to minimum
spindle speed. N (RN depends on max. & min.
max
RN  spindle rpm, that can be
N min related to cutting speeds and
diameters being machined)
We get 1000vmax
N max 
Dmin vmax Dmax
1000vmin RN    Rv  RD
N min 
Dmax vmin Dmin

Cutting speeds used on m/c tools

Range of diameters being machined

 Preliminary steps in the Design of Multi
stage Gear Box
 Higher Rv (cutting speed)
 loss of productivity

(not available (or) not economical)

 Low Rv below particular cutting speed limit tool life reduces
(requires frequent re grinding- productivity loss)
 Generally Rv (cutting speed) kept within reasonable limits
 RD=4 (Covers 85% of the work pieces)
 RD=6 (Covers 92% of the workpieces)
 Based on these parameters RN can be determined
 For Lathes, boring and milling m/c’s RN Large
 (different -kind of job can be machine)
 Grinding machine R not greater than 2
Preliminary steps in the Design of
Multi stage Gear Box
 2. Selection of GP ratio:

 Discussed previously
 To decide Break of speed steps and no.of
transmission stage:
 For a given value of RN and φ
 No. of speed steps log( RN  ) (Answer may not be
Z
 log Z  2
n
whole number- rounded off)
 multiple of 2 & 3
Range of Z Z Rounded value
5 to 7 6 (2 x 3)
7 to 8.5 8 (2 x 2 x 2 )=23
8.5 to 10 9 ( 3 x 3 ) = 32
10 to 13 12 (2 x 2 x 3 ) = 22 x 3
13 to 16 16 (2 x 2 x 2 x 2 ) = 24

 In general value of Z selected on basis of equation Z  2 n1  3 n2