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EXAMPLE 1
A three stage gear box with twelve speeds is to be designed based on R10 s1eries with a
minimum spindle speed of 125 rpm. The electric motor is connected to the gear box through
a belt drive and runs at 1440 rpm and transmit power of 5 KW. Using standard spindle
speed,
a.)
b.)
c.)
d.)
e.)
f.)
Possible arrangement is
2n 2n 3n
1
z=
= 2 3
10
10
=1.26
N10=800*1.26=1000 rpm
N11=1000*1.26=1250 rpm
N11=1260*1.26=1600 rpm
So begin with considering the preferred structure diagram as shown in figure
=4<8
This value is less than 8 and hence the structure diagram is suitable.
The speed diagram for the same has been shown in figure
From the above speed diagram, it can be seen that in stage 2 and 3 the speed reduction of the gear pair
would be maximum
The gear ratio would be
315/125=2.52
It is seen that the gear drive is used to connect the motor with the input shaft of the gear pair.
The motor speed was 1440 rpm whereas the input shaft from the speed diagram is 1600 rpm.
Thus, if the pulley connected to the motor has a diameter D M and that connected to the input shaft.
The gear box has diameter D1, then the pulley diameter would be in the ratio
D1/DM=NM/N1=1440/1600=0.9
The gear layout should be as shown in the figure
Zb=1.6Zb
Za+Za=Zb=Zb
3Za = 2.6Zb
Za = 1.154 Zb
To determine the integer value of no of teeth on gear the table is shown below
Za
18
19
20
Za=2Za
36
38
40
Za+Za
54
57
70
Zb=1.154Za
21
22
23
Zb=1.6Zb
33(R 1.57)
35(R 1.59)
37(R 1.61)
Zb+Zb
54
57(suitable)
60
Z
e
18
Ze=2.54Ze
46(R 2.55)
Ze+Ze
64
Zd=1.362Z
e
25
19
48(R 2.526)
67
26
20
51(R 2.550)
71
27
21
53(R 2.524)
74
29
22
56(R 2.545)
78
30
Zd=1.6Zd
39(R
1.560)
40(R
1.577)
44(R
1.630)
46(R
1.586)
48(R 1.60)
Zd+Zd
64
Zc=1.77Z
e
32
Zc=Z
c
32
Zc+Zc
67
34
34
68
71
35
35
70
74
37
37
74
78
39
39
78
64
GEAR RATIO
CORRECTED
1
C
C
d
d
1.6
e
e
2.545
ACTUAL SPEED
SHAFT
800,1006.3
800.1006.3
800,1006.3
800/1.6=500
1006.3/1.6=628.9
800,1006.3
800/2.545=314.3
1006.3/2.545=395.4
2
3
2
3
3
2
3
3
To determine the number of teeth in the third stage, the input speeds are 314.3, 395.4, 500, 628.9, 800
and 1006.3 rpm.
Now for the third stage
Zf/Zf=Nf/Nf=314.3/500=0.629
Zg/Zg=Ng/Ng=314.3/125=2.51
The largest ratio for this stage would be for gears g and g
Zf=0.629 Zf
Zg=2.51 Zg
Zf+Zf=Zg+Zg
1.629 Zf=3.51 Zg
Zf=2.155 Zg
To find the number of teeth on gear following table is given
Zg
Zg=2.51Zg
Zg+Zg
18
45(R 2.50)
63
19
48(R 2.53)
67
20
50(R 2.50)
70
In the present case we selecting gear with Zg=20
Zf=2.155Zg
39
41
43
Zg=0.629Zg
24(R 0.615)
26(R 0.634)
27(R 0.628)
Zg+Zg
63
67
70
GEAR RATIO
0.628
g
g
2.5
ACTUAL SPEED
314.3,395.4,500,628.9,800,1006.
3
314.3/0.628=500.5
395.4/0.628=629.6
500/0.628=796.2
628.9/0.628=1001.4
800/0.628=1273.9
1006.3/0.629=1602.4
314.3,395.4,500,628.9,800,1006.
3
314.3/2.5=125.7
395.4/2.5=158.2
500/2.5=200
628.9/2.5=251.6
800/2.5=320
1006.3/2.5=402.5
SHAFT
3
4
4
4
4
4
4
3
4
4
4
4
4
4
Nth
125
160
200
250
315
400
500
630
800
1000
1250
N=(Nact-Nth/Nth)*100
0.56
-0.13
0.64
1.59
0.63
0.10
0.10
-0.06
-0.47
0.14
1.91
1602.4
1600
0.15
MINIMUM SPEED
1440
1600
800
31403
125.7
TORQUE
33.157
29.842
59.683
151.914
379.845
(Nm)
A multi speed gear box is to be designed for a small m/c tool having speeds varying from 63
rpm to 630 rpm. The recommended series of speeds is R5 using the standard spindle speeds.
The gear box is connected to a motor by a pair of pulleys. Assuming the motor speed to be
1440 rpm, determine ratio of the pulleys diameter required. Draw a suitable structure diagram
and speed diagram and determine number of teeth on each gear.
GIVEN DATA
Nmax=630 rpm
Nmin=63 rpm
NM=1440 rpm
Preferred series =R5
=
5 10
=1.585
number of speeds=6
so the different speed of the m/c tool are given below
N1=63 rpm
N2=63*1.585=100 rpm
N4=158*1.585=250 rpm
N5=250*1.585=395 rpm
N6=395*1.585=630 rpm
Number of stages=2
The structure diagram is shown in the figure
=2.51<8
From the above speed diagram, it can be seen that in stage 1 and 2 the speed reduction of gear
pair would be maximum
Zb/Zb=Nb/Nb=630/250=2.52
Za+Za=Zb+Zb
Zb=1.417 Za
Za
Za=3.98Za
Za+Za
Zb=1.417Zb
Zb=2.52Zb
18
72(R 4.0)
90
25(R 1.39)
63
19
76(R 4.0)
95
27 (R 1.42
68
So from the above table the number of teeth on gear a is taken as 19 teeth.
For the number of teeth on second stage following procedure is given
Zc/Zc=Nc/Nc=250/100=2.5
Zd/Zd=Nd/Nd=250/158=1.585
Ze/Ze=Ne/Ne=250/395=0.632
Zc+Zc=Zd+Zd=Ze+Ze
Zd=1.35 Zc
Zb+Zb
98
95
Ze=2.13 Zc
For the calculation of the teeth interpolation is required which is given in below table
There for the number of teeth to be taken for the gear c is 20.
Zc Zc=2.5Z Zc+Zc Zd=1.35Z Zd=1.585Z Zd+Zd Ze=2.13Z Ze=0.632Z
c
c
d
c
e
1 45
63
24(R
38(R 1.583) 62
38(R
24
8
1.33)
2.111)
1 48(R2.526 67
26(R
41(R 1.576) 67
41(R
26(R 0.634)
9 )
1.44)
2.157)
2 50
70
27
43
70
44
26
0
T
6
2
6
7
7
0