Input power (P) = 22 KW Input RPM = 1400 rpm Reduction Ratio = 31.

5:1

3 Stage speed reduction gear box

Reduction ratio per stage i.e i1 = i2 = i3 = = 3.1582 Design for stage I:Speed for design of stage I:

N2 = 443.29 rpm

Step I: Material selection Element Pinion Wheel Material selection 40Ni2Cr1Mo28 15Ni2Cr1Mo15 [b] 400 320 [c] 1100 950

Step II: Determination of no of teeth on pinion and wheel. = 20 = 18 Z1 = no of teeth on pinion. Z2 = no of teeth on wheel. Z1 = Z2 = = = 17.09 18 18 = 56.3476 57

= 3.1052

Strength of pinion and wheel: Y1 = * +

Where Zv1 is virtual no of teeth Zv1 = = = 20.9244

Y1 = 0.34687 Now, Y2 = ]

Where Zv2 is virtual no of teeth Zv2 = = = 66.26

Y2 = 0.44056

Strength of pinion: S1 = [b1] x Y1 = 0.34687 x 400 = 138.74 Strength of wheel : S2 = [b2] x Y2 = 0.44056 x 320 = 140

Hence, the pinion is a weaker element. Now considering pinion we find the required dimensions.

Step III: Determination of module. M

[Mt] = Mt x S.F [Mt] = = = 165.06641 N-m

= 165.06641 x 103 N-mm m = 20.(rigid casing)

1.4895

M = 2

Step IV : Checking for surface stress failure: c = 0.7( as we know a = =

( ( )

= 78.8597 mm E = 2.15 x 105 N/mm2 i = 3.1582 b = m x m = 40 [Mt] = 165.06641 x 103 N-mm substituting all the above values in the above equations, we get, c = 0.7, - [
( )

= 1263.177 N/mm2 > [c]=1100 N/mm2 Design is not safe. Hence we increase the module by 1 mm. m = 3mm The center distance is a=
( )

= 118.289

b = m x m = 20 x 3 = 60mm c = 0.7* +
( )

= 686.696 N/mm2 < [c] = 1100 N/mm2 Hence design is safe.

Step V: Checking for failure in dynamic conditions: Fs Fd Fs = = = 449543.52 N Ft =

Where Vm = Ft = 5.5577N

= 3958.406 m/s

By buckinghams dynamic load formula Fd = Ft + [ where; c = 593 b = m x m =60 = 5.5577 + [ = 30410.166 N Fs > Fd Hence design is safe
(( ( ) ) ) (( ( ) ) )

Step VI: Checking for wear failure. Fw = where; b = 60

Z1 = 18 m = 3 = 1.5190 * +

Q = k =

= 1.3749 Substituting all the values in Fw, we get

Fw = Fw = 7481.0273

Fw < Fd ; Hence design is not safe. Increasing the value of m = 5 and m = 40 Fw = 41561.2632 N/mm2 Fw > Fd Hence design is safe.

Step VI: Principle dimension: 1. mn = 5mm 2. mt = = 5.2573 mm 3. Center distance(a) = 4. 5. 6. 7.

( )

= 197.1491 mm

Heignt factor(f)o = 1 Bottom clearance(C) = 0.25mn = 1.25 mm Tooth depth(h) = 2.25 mn = 11.25 mm Pitch diameter : a. Pinion = b. Wheel = = 94.62 95mm = 299.66 300mm + + 20.92 21mm 309.93 310mm

8. Tip diameter: a. Pinion = * b. Wheel = * 9. Root diameter: a. Pinion = * b. Wheel = * 10. No of teeth on pinion = 18 11. No of teeth on wheel = 57 +mn 2C = 82.1316 85 mm +mn 2C = 287.1667 290 mm