MULTI SPEED GEAR BOX

What is a Speed reducer?

 Speed reducer is a gear mechanism contained in a separate casing

 It provides constant speed ratio, to reduce the angular speed of output shaft as compared with
that of input shaft.

Name the types of speed reducers.

Speed reducers can be classified as:

 According to the type of drive used: Spur, helical, bevel and worm gears.
 According to the number of stages:
 Single stage reduction speed reducers: one set of gear such as one pinion and one
wheel can be operated
 Multi-stage reduction speed reducers: two or more set of gears can be employed.

What is a Step-up gear mechanism?

 Speed reducer is a gear mechanism contained in a separate casing

 It provides constant speed ratio, to increase the angular speed of output shaft as compared with
that of input shaft.

What is a gear box?

 Practically it is not possible and advisable to provide to provide a number of machine tools having
single speed only for machining different kinds of metals.
 In order to obtain many cutting speeds in a single machine tool, a special device, will be attached
in between the prime mover such as motor or engine and the work holding device such as chuck
or spindle etc.
 This device is known as gear box. Here the speed of the output shaft is varied in discrete steps:
there may be increased and/or decreased speeds, from the input speed.

What are the main components of a gear box?

 Gears for getting different speeds

 Shafts for mounting gears
 Bearings to support shafts
 Spacers to maintain the distance between gears
 Levers for changing the position of gears for engagement
 Gear box housing used for covering all the inner components
 Oil seals for lubrication

What is the function of spacers in a gear box?

 Spacers are sleeve like components which are mounted on shafts in between gears and bearings
or one gear and another gear.
 The function of spacers is to provide the necessary distance between the gears and the bearings
What purpose does the housing of gear box serve?

 Gear-box housing or casing is used as container inside which, the gears, shafts, bearings and
other components are mounted.
 Also it prevents the entry of dust inside the housing and reduce noise of operation. That is, the
housing safe-guard the inner components

What are the different methods used for obtaining different speeds of machine
tool spindle?

 By using a gear box mechanism

 By using a cone pulley arrangement
 By using a variable speed electric motor, and
 By hydraulic operation

What are uses of a multi-speed gear box? (or) What is the purpose of a gear box
in a machine tool?

 To provide the designed series of spindle speeds

 To transmit the required amount of power to the spindle
 To provide smooth silent operation of the transmission
 It should have simple construction
 Mechanism of speed gear boxes should be easily accessible so that it is easier to carry out
preventive maintenance.

What are the methods for changing speed in gear boxes?

 The two important methods widely used are: Sliding mesh gear box and constant mesh gear box.

What are the applications of gearbox?

 It is used in automobile where low speed is required at starting and stopping and high speed
during running.
 It is used extensively in machine tools. It will be attached in between the prime mover such as
motor or engine and the work holding device such as chuck or spindle etc. Here the speed of the
output shaft is varied in discrete steps: there may be increased and/or decreased speeds, from
the input speed.

What are preferred numbers?

 Preferred numbers are the conveniently rounded off values derived from geometric series. There
are 5 basic series, denoted as R5, R10, R20, R40 and R80 series.
 Preferred numbers assist the designer in avoiding the selection of sizes in an arbitrary manner.
  Each series has its own step ratio, i.e., series factor

Basic series Step ratio ‘’

R5 1.58
R10 1.26
R20 1.12
R40 1.06
R80 1.03
 The series of preferred numbers is obtained by multiplying a step ratio with the first number to get
the second number. The third number is obtained by multiplying a step ratio with the second
number. Similarly the procedure is continued until the series is completed.

Why are the speeds of a gear box arranged in geometric progression?

 The speed loss is minimum ( Speed loss = Desired speed-available speed)

 The number of gears to be employed is minimum
 G.P. provides a more even range of spindle speeds at each step.
 The layout is comparatively very compact
 Productivity of a machining operation, i.e., surface area of the metal removed in unit time, is
constant in the whole speed range.
 G.P machine tool spindles can be selected easily from preferred numbers. Because preferred
numbers are in Geometric progression.

Define geometric progression. (or) What is step ratio (or series ratio or
progression ratio? (or) How is the progression or step ratio found?

 To provide required cutting and feed rate in machine tools, discrete speeds are arranged in
geometric progression.
 The ratio between the two adjacent speeds is known as ‘step ratio’ or ‘progression ratio’. It is
denoted by .
If n1, n2, n3….. nn are the spindle speeds arranged in geometric progression, then
n2 / n1 = n3 / n2 = n4 / n3 = ……… nn / nn-1 = constant = 
nmax / nmin =  n-1

Note: Permissible deviation = 10 (-1)%

What is meant by structural formula?

Z = p1(X1) p2(X2) p3(X3) p4(X4) where X1 = 1, X2 = p1, X3 = p1 p2, X4 = p1 p2 p3

Where Z = no. of speeds available at the spindle.

Write the various structural formulae for a 12 speed gear box.

 1x2x2x3 or 1x2x3x2 (or)3 1x3x2x2

What are the principles to be followed in achieving an optimum design in multi
speed gear box?

To avoid excessively large diameter of the wheel and also to limit the pitch line velocity of the gear,

 Number of gears on the last shaft (spindle) should be the minimum

 Number of gears on the shafts should not be more than 3, though in exceptional cases it may be 4;
 It is preferable to have nmax  ninput > nmin in all stages
 For stable operation, the speed ratio of any stage should not be greater than 8.
i.e., nmax / nmin =  n-1  8
imax = nmax / ninput =  2
imin = nmin / ninput =  1/4

 The transmission ratio between the spindle and the shaft preceding it should be the maximum
possible, i.e., speed reduction should be maximum possible.
Follow for all stages, imax = nmax / ninput =  2 and imin = nmin / ninput =  ¼
If it is not possible, keep nmax / ninput < nmin / ninput , OR keep nmax / ninput = nmin / ninput
But never keep nmax / ninput > nmin / ninput

What is speed (or structural) diagram of a gear box?

 Speed diagram or structural diagram is the graphical representation of different speeds of output
shaft, motor shaft and intermediate shafts.

What does the ray-diagram (or kinematic layout) of a gear box indicate?

 The ray diagram or the kinematic layout shows the arrangement of gears in a gear box
 It also provides information like number of number of speeds available at each spindle and the
number of stages used.
.

In a gear box, for a set of gears, if the centre distance and module are same, then
the sum of teeth of engaging pair will be equal.

What are the methods of lubrication in speed reducers?

 Splash or spray lubricating method, and

 Pressure lubrication method
Draw a typical speed diagram of a gear box providing an output of 12 spindle speeds.

Draw a simple layout of arrangement of sliding gears.

Output shaft diameter of a gear box will be small. True/False. Justify.

Write the applications of planetary reduction gears.

In a speed reducer, the centre distance is 30 mm, the module of the gears is 1 mm. If
the speed ratio is 2, find the no. of teeth of both pinion and gear.

Sketch a double stage spur gear speed reducers.

Draw a simple sketch of a spur gear speed reducer gear box arrangement.
Assembly drawing of a Double helical gearbox