Notes on

Design of a Bevel-Helical Gear Box

Calculation of Loads on Shaft,
Bearing Selection & Shaft Design

Important Note:
Sample calculations are shown on a design problem of a Two stage
Helical Gear box. In designing bevel-helical two stage gear box
calculations will be similar. How to estimate loads on gears and
finally on an intermediate shafts, having the bevel gear and helical
pinion, is shown later in this note.

Design of an Industrial General Purpose Reduction Gear Unit :

Problem for Monday Group (2014) :

Data: The TWO

TWO- stage (1st stage Bevel and
2nd. Stage helical) reduction gear box has
the following specifications.
(20 to 22 different problems).
GROUP

POWER
(kW)

INPUT
RPM

OUTPUT
RPM

I
A, B, C, D,

12

1500

170

II
E F
E,
F,G,H
GH

10

1800

200

B,F,J,N,R

III
I, J, K, L

09

1450

125

C,G,K,O,
S, V

IV
M,N,O,P

07

1200

125

D,H,L,P,T

V
Q,R,S,T
VI
U, V

05

1500

140

06

950

100

Sub
Group
A,E,I,M,
Q, U

DUTY
Description
Precision,
Intermittent,
No shock
General,
C ti
Continuous,
Medium shock
General,
Intermittent,
Heavy Shock
Precision,
Continuous,
Medium Shock

OVERHAUL
TIME
2 years

Z3

Z4

Z1
Z2
LUBRICATION
Forced
Oil Sump
Oil Sump

Assembled plan view

(Not of the same one as below)

Forced

Horizontal input and vertical output (Forced Lubrication)

1stt. stage ratio

i should
h ld not exceed
d 3.
In general non co-axial horizontal input
and output (except otherwise mentioned).
Photographic view of 2-stage (Bevel Helical) gear box.
(Top cover open)

Horizontal InputOutput.

22

A Typical Helical Gear Box Design Problem

A helical gear reduction unit has to
transmit 31 Nm input torque at 1500 rpm
with a total reduction of about 37 to 40.
At starting the torque may go as high as
200%.
The material for pinion is EN 19A and for
gear wheel it is EN 18A.

Assembled plan view is of 2-stage gear box.

The gear box may be an ordinary

industrial class unit preferably with
uncorrected gears.
It is continuous duty with medium shock
and overhauling time is Two years.
(Alternatively -the bearing life should not
be below 10,000 hours).

First Stage

Photographic plan view is of 2-stage gear box.

A Typical Helical Gear Box Design Problem

1st. Step.

Selection of number of stages with respect to Total Transmission Ratio.

In the present problem Total Transmission Ratio,

it

= 37 to 40.

Considering
g not more than ratio 6 in a stage
g (p
(particularly
y in 1st. Stage)
g ) a
total ratio above 6 and below 36 can be managed in two stages.
For a Ratio above 36, usually three stage reduction is preferred.
However, allowing a ratio little more than 6 in second stage (which is done
very
e often to reduce
ed ce cost) a total ratio
atio of 37 to 40 is done in two
t o stages.
stages
Now, the ratios are to be selected in a
way that the size of the gear box
becomes optimum.
Optimization technique to be adopted
in this regard.
The process is tedious.
tedious However,
However
experienced designer can do it with a
little manipulation and trial and error
on the selection of the stage
reductions
reductions.
Assembled plan view is of 2-stage gear box.

A Typical Helical Gear Box Design Problem

1st. Step (Contd).

Selection of number of stages for a Total

Transmission Ratio
= 37 to 40.
40
t

Considering two stage reduction the numbers of teeth of pinions and

gears were selected as follows:
1st. Stage:

Z 2 81

4.76
i1
Z 1 17

2nd. Stage:

i2

Z 4 131

8.19
Z 3 16

Therefore, total ratio becomes:

ii2

ii1

it

Z2 Z4 81 131

Z1 Z3 17 16

Assembled plan view is of 2-stage

2 stage gear box
box.

1
0
.
9
3

4.768.19
This is acceptable.

A Typical Helical Gear Box Design Problem

1st. Step (Contd).

In choosing the numbers of teeth and stage

ratios,
ti
nott only
l the
th size
i optimization
ti i ti
is
i
considered but also the roundness in centre
distances with uncorrected gears is taken
care* of:
2nd. Step.
In next step gears are designed as described
in earlier lectures.
Estimated 1st. Stage module is

mn1 3 mm

and
d 2ndd. Stage
St
module
d l is
i

mn 2 4 mm

Assembled plan view is of 2-stage gear box.

With a suitable selection of helix angle*, 1 2 11 2652 , for which

cos 1 cos 2 0.98
0 98 and centre distances become:
o

and

A1

( Z1 Z 2 ) mn1 (17 81) 3

98 3

150 mm*
2 cos 1
2 0.98
2 0.98

A2

( Z 3 Z 4 ) mn 2 (16 131) 4 147 4

300 mm*
2 cos 2
2 0.98
2 0.98

Finalized gear data are now recorded in a tabular form (as in next slide).

Gear Data

2nd. Step (Contd) .

First Stage

Sl. No.

Description

1.

,, Number of Teeth

2.
3
3.

m n , Normal module

4.

5
5.
6.
7.
8.
9.
10.

dd

Pinion

Gear

17

81

16

131

Involute Full Depth, Un corrected

4 mm

11 2652
RH
LH
30
3.0
o

f a mn

Dedendum Height (mm)

da

Gear

3 mm

, Helix Angle

Addendum Height (mm)

dp

Pinion

20 o

Profile

Second Stage

1.0 mn

fd mn

11o 2652
LH
40
4.0

3. 75

1.25 mn

RH

5.0

, Pitch Circle Diameter (PCD)

(
) (mm)
(
)

52.04

247.96

65.306

534.69

, Addendum or Tip Diameter (mm)

58.04

253.96

73.30

542.70

Dedendum or Root Diameter (mm)

44.54

240.46

55.30

524.70

63

58

68

63

, Face width. (mm)

11.

Material

EN 19A

EN 18A

EN 19A

EN 18A

12
12.

S f
Surface
H
Hardness
d
(BHN)

350

300

350

300

(Through Hardened)
p and g may be added to subscript of Nomenclature to indicate pinion and gear respectively. Similarly 1 and 2 can
7
be added to indicate stage of Gear.

3rd. Step.

Layout & Bearing Selection

Layout of pinion and gears is made in next step.

Shafts are automatically shaped.

Then Bearing types are chosen taking

into account service severity and life.
Taper
p Roller Bearing
g to be used in p
pair.
Other Bearings- may be used in pair
or in combination.

Distance between Bearing

(Taper Roller) supports.

p both spherical
p
roller and
For an example
ball bearing can be combined with
cylindrical roller bearing in the other end.
Choice depends
p
on type
yp of loading
g mainly.
y

Locking of bearings with shaft and

housing is to be decided at this stage.
Spherical Roller
Bearing

Cylindrical Roller
Bearing

Sharing
h i
off reaction
i
lloads
d b
by b
bearings
i
depends also on of bearing Locking
arrangement.

Ball Bearing
(Deep Groove)

With distance between bearing supports

the shaft is considered as simply

supported beam.

3rd. Step:

Layout & Bearing Selection (Contd..)

Layout of a single stage Gear Box

Assembled plan view of

a 2-stage gear box.

Plan View -Schematic

3rd. Step:

Layout & Bearing Selection (Contd..)

Roller Bearings:
Assembled plan view of
a 2-stage gear box.

(Not taper roller

in this case).
case)

Considering
C
id i
bearing widths,
15 to 25 mm
((Typical)
yp
)

15 to 25 mm
(Typical)

10 to 15 mm (Typical)

53

50
1 8
178

Layout of Intermediate Shaft (Referring to Design Problem)

finally distances
are marked.
marked
10

4th. Step. Loads on Gear, Pinion Teeth and on Bearings.

Tangential Load:

2T
Ft
dp

Z mn
d

cos

Ft
F

Normal Load:
t
tn
cos
n

Ft tan

dp

Forces on Helical Spur Gear Tooth.

FFt
t

Fn

Ftn
Ft sec .sec n
cos n

Radial Load:

Fr = Fn .sinn
= Ft sec.sec

i n
n .sin

Fr Ft sec .tan n
( Ft tan )
Axial Load:

Fa Fn ssin Ft tan
Fn Ft sec .sec n

11

Force Diagram for Bevel Gear :

For Your Reference.

Tangential Load:

2T
Ftg
d pg

d pg Z g ( Bevel ) mBevel
Normal Load:

d pg 2
Fag

Ftg

Fng Ftg sec n

R di l Load
Radial
L d ((gear):
)

g
Frg

Frg = Ftg .tann .cosg

(p
)
= Fap , Axial Load (pinion).
Axial Load (gear):

Fag = Ftg .tan

tann .sing

Fng

Frp
As

, Radial Load (pinion).

g + p = 90 o
12

Calculation of Loads and Reactions on Shaft & Bearing

4th. Step (Contd):

For Intermediate Shaft (Referring to Design Problem)

Torque
o que (T n 2) Flow
o Path
at

Loads and reactions are calculated on the

basis of Nominal Torque & approximate
bearing width = 25 mm.

Z 2 (81)
pcd 248 mm

Bending
g Moment due to Axial Load:

M a 2 Fa 2

Z 3 (16)
pcd 65.3 mm

53

50

M a 3 Fa 3

178
Intermediate Shaft with gears and Bearings

RVL Fr 3

Ft 2

Ft 3

Fr 2

d p3
2

240.65 0.2479
30 Nm
2

914 00.0653
0653
30 Nm
2

For moment equilibrium (horizontal plane) about R

RVR

Fa 3 Fa 2

RHR

RHL

1683 0.125 443 0.05

30
30

0.178
0.178
0.178 0.178
1182 124.4 168.5 168.5

N
6
.
0
2
7
=

RHL

d p2

From force equilibrium-

= 914 N

= 520 N

Similarly computing for vertical plane:

=443 N

2
Fa Fa

M a2

=1683 N
2

= 1193.5 N

r
3
Fr F

3
2
Ft
Ft

= 4533 N

M a3

RHR

= 240.65 N

Applied Loads, Reactions & Moments due to Axial Loads

RVL

= 3518.5 N

RVR

=2208 N
13

5th. Step:
Bearing Life Estimation
For Intermediate Shaft (Referring to Design Problem)
Equivalent Load Acting on bearing is
Torque
q (T n 2) Flow Path
expressed as:
P C XVF YF
1

Z2 (81)

C
L N 10 6
P

Z 3 (16)

53

= 914 N

Fa F a

= 240.65 N

=443 N

m
N
0
3

Applied Loads, Reactions &

Moments due to Axial Loads

Fr

M a2

Fr 2

=1683
683 N

RVR

Fa 3 Fa 2

Fr

2
Ft Ft

= 4533 N

= 1193.5 N

M a3

Hours

Loads from Gear teeth were estimated as:

Intermediate Shaft with gears and Bearings (Plan View)

Ft 2

Revolution

LN
L H
N 60

50

178

Ft 3

Life in hours is then estimated as:

pcd 65.3 mm

RHL

RVL

Life of Rolling Element bearing in

Number of Revolution is expressed as:

pcd 248 mm

Fr 3

RHR

Also, moments due to axial forces were

estimated as: Ma2 Ma3
Finally Bearing reactions (radial) were estimated as:

RHL = 720.6 N

RHR

= 520 N

RVL = 3518.5 N
RVR =2208 N

Bearing reactions (axial) yet to be estimated.

14

5th. Step (Contd):

Bearing Life Estimation

The Final bearing reactions:

From details of loading resultant right
b
bearing
i
(radial)
( di l) reaction
ti
is
i calculated
l l t d as:

Radial reactions are

not in same plane.

2
2
Fr R RVR
+ RHR
= 2208 2 + 520 2

2268.4 N

Fa Net

o
7
5
.
1
1

Fr L

= 914 N

= 240.65 N

RVL = 3518.5 N
RVR =2208 N

Details of loading & Resultant bearing Reactions.

R HR

RVR

2
2
RVL
RHL
3518.52 720.62

3591.5 N
and,

L tan 1 RHL RVL

Resultant axial load may act only on one

bearing irrespective of its direction (i.e.,
direction of shaft rotation).
rotation)
It depends on bearing locking arrangement.
In this case it is on right bearing which is
with less radial load.
load
Net axial load

Fa Net Fa Fa 3 Fa 2

N
5
3
.
3
7
6

RHR = 520 N

=443 N

Fr 2

RHRFa

2
Fa Fa

RHL = 720.6 N

=1683 N
2

= 1193.5 N

r
3
Fr F

3
2
Ft
Ft

= 4533 N

Ft 2

Similarly, F

rL

o
7
7
5.
5
11
11

Fa 3

Ft 3

RVR

Fa 2

derived as R tan

o
o
5
5
2
2
.
3
3
1
1

RVL Fr 3

Fr

Bearing Reactions (& Locking)

RHL

Fr R

50

53

It is acting at an angle R with vertical plane,

5
2
.
3
1

Fr L

15

Bearing Life Estimation

Consider deep groove
ball bearing
g SKF 6309
as both end supports
of intermediate shaft:
Equivalent load on
left bearing:

N
N
5
3
8
.
7
3
6
7
6
=

d=55.3 mm

5th. Step (Contd):

Bearing
ea g
No.
6309

2268 4 N
2268.4
FFrrRR 50

1.5 (1.0 1 3591.5 Y 0)

N
5
2
.
7
8
3
5

N
5
7
7
.
5
5
5
2
2

N
N
0
0
2
2
6
6
3
3

Fr L 53
3591 5 N
3591.5

6
.
1
=
Y
&
1
=
X

PL C1 XVFr ( L ) YFa ( L )

FaFa

Inner
Dia.
(d)

Outer
Dia.
((D))

Width
(B)

Corner
Radius (r)

Basic Load Capacity

Approx.

Dynamic
C

Static
Co

mm

mm

mm

mm

Newton

Newton

45

100

25

2.5

40130

29200

[Note: C 1 is taken as
1.5 considering medium
shock load (given) on
the estimated load on
bearings based on
nominal torque.]

Life (in hrs) of left bearing:

s
r
h
0
8
8
,
1
2
=
s
r
h
6
0
1

0
8
8
1
2
0
.
0

(40130 / 5387.5) 3 10 6

N 60
(1500 17 / 81) 60
L

L N (L)

16

Bearing Life Estimation

5th. Step (Contd):

Ball bearing SKF 6309 is selected for both end supports of intermediate shaft:

,
N
4
6
.
8
1
0
5

y, estimated equivalent
q
load and
Similarly,
life of right bearing:
PR 1.5 (1.0 1 2268.4 1.6 673.35)

RR
HH
L

FaFa

.
s
r
h
7
6
0
,
7
2

.
s
r
h
0
8
8
,
1
2

Note: Estimated lives of both bearings are

more or less
l
same & above
b
the
h
FFr rR R 50
2268.4 N
required specified life (10,000 hrs).

N
5
7
.
5
5
2
2

N
N
0
0
2
2
6
6
3
3

Fr L 53
3591.5 N

s
r
h
7
6
0
,
7
2
=
s
r
h
6
0
1

7
6
0
7
2
0
.
0

N
N
5
3
8
.
7
3
6
7
6
=

(40130 / 5018.64) 3 10 6

(1500 17 / 81) 60

Now it can be examined the life with bearing

g of lower load capacity:
p
y
Bearing
No.

Inner
Dia. (d)

Outer
Dia. (D)

Width
(B)

Corner Radius
(r) Approx.

Basic Load Capacity

Dynamic
C

Static
Co

mm

mm

mm

mm

Newton

Newton

6309

45

100

25

2.5

40130

29200

6308

40

90

23

2.5

31000

21400

6211

55

100

21

2.5

32100

25415

As the root diameter of

pinion is 55.39 mm then
a bearing of id 55 mm
(maximum) may be
selected.

If SKF 6308 or 6211 is selected then life will be reduced by (C6309/C6308 or 6211)3 i.e.,
2.17 or 1.95 times respectively, which is acceptable.
However, design with SKF 6309 will perhaps be preferred.

17

6th. Step Shaft Design

Bending moment on Intermediate Shaft due to Tangential Forces

(Vertical Plane)

In case of gear box the diameters of a shaft is

dominated by the size (root diameter) of the
integral pinion and optimum bearing size mainly.

The length is determined by the placement of

gear, pinion, bearings, coupling, key size,
seals
l etc. and
d the
h optimum
i
gap required
i d
between two consecutive elements.
The a shaft is automatically shaped
during first layout and bearing
selection, as shown earlier.

53 mm

75 mm

50 mm

Layout

RVL

= 3518.5 N

RVR

=2208
2208 N

2
Ft

3
Ft

Therefore, instead of designing the

shaft the critical sections are verified
for developed stresses.

= 1193.5 N

= 4533 N
Load Diagram.
1014.5 N

Bending
e d g Moment
o e t ((respective
espect e plane)
p a e) Calculation
Ca cu at o
m
N
5
.
6
8
1

M
B

V
3
P

3518.5 0.053

Shear Force Diagram (SFD).

m
N
4
.
0
1
1
m
N
5
.
6
8
1
-

m
N
4
.
0
1
1

V
V
2
2
G
G

M
B

3518.5 0.128 4533 0.075

=2208 N

=3518.5 N

Bending Moment Diagram (BMD).18

Shaft Design (Contd)

Bending moment on Intermediate Shaft due to Tangential Forces

(Horizontal Plane)

Bending Moment (respective

plane) Calculation (Contd)
(Contd )
Considering from left support Bending
Moment just left of section 3-3:

53 mm

75 mm

And just right of section 3-3:

m
N
0
2
a3
M =

m
N
0
3
a3
M =

m
N
2
.
8
3

H
3
P
M
B

720 0.053

50 mm

2 -2

Fr

m
N
2
.
8
6
=

++
H
H
3
3
P
P
M
B

0
3
+
2
.
8
3
=

3-3

Layout

=1683 N

m
N
6
2

+
H
2
G
M
B

=443 N

RHR= 520 N

Load Diagram.
= 720 N

943 N

520 N
443 N

Shear Force Diagram (SFD).

m
N
6
2

m
N
2
.
8
6

4.1 30

And BM just right of section 2-2:

m
N
4
-

H
2
G
M
B

720 0.128 1683 0.075 30

RHL = 720 N

Fr

Similarly, BM just left of section 2-2:

3-3
2 -2
Bending Moment Diagram (BMD).

19

6th. Step (Contd.) Shaft Design

Second Step: Resultant Bending
Moment and Critical Section
It is to be noted that in a rotating shaft outer layer
experiences maximum flexural bending stress.

R
79 mm

As bending stress is expressed by bending moment

divided by section modulus, it is necessary to verify
those for probable critical sections.

75 mm

3-3

3 -2

50 mm

2 -2

Layout

m
N
4
.
0
1
1
m
N
5
.
6
8
1
-

In the Intermediate shaft, any of sections 2-2,

3-2 & 3-3 may be critical i.e., experiences
maximum bending stress.

53 mm

Bending Moment-Vertical Plane.

m
N
6
2

m
N
2
.
8
6

3-3
2 -2
Bending Moment-Horizontal Plane.

20

6th. Step (Contd.) Shaft Design

Next: Resultant Bending Moment
and Critical Section ((Contd))
Reasons are as follows:

R
79 mm

Among these three sections, through which

full torque transmits, section 3-3 has
maximum bending moment, although it has
also the maximum diameter.

75 mm

3-3

3 -2

50 mm

2 -2

Layout

m
N
4
.
0
1
1
m
N
5
.
6
8
1
-

It has medium stress concentration as it is

roots of teeth.

53 mm

Sections 2-2 & 3-2 have equal diameters but

diff
different
t stress
t
concentration
t ti
factors.
f t

Again 2-2 usually experiences less BM.

m
N
6
2

Therefore, section 2
2-2
2 may be severe than
section 3-2 in stress concentration point of
view.

Bending Moment-Vertical Plane.

m
N
2
.
8
6

At section 3-2 there is step, where as at

section 2-2 a there is keyway.

3-3
2 -2
Bending Moment-Horizontal Plane.

21

6th. Step (Contd.) Shaft Design

Resultant Bending Moment and Critical Section (Contd)

3
3

6 8 .2 2 1 8 6 .5 2

m
N
6
.
8
9
1
=

M
B

Resultant bending moment at 3-3:

79 mm

53 mm

Resultant bending moment at 2-2:

2 6 2 1 1 0 .4 2

2
3

2 -2

Layout

Bending Moment-Vertical Plane.

N
N
6
6
2
2
m
N
2
9
.
3
2

m
N
2
.
8
6

2 3 .9 2 2 1 3 9 .8 1 2

2
3

m
N
4
8
.
1
4
1
=

M
B

mm
NN
22
99
.
33
22

6
4
0
.
0
3
8
6
1
0
3
+
9
9
0
.
0

6
.
0
2
7
=

2
3

MM
BB

m
N
1
8
.
9
3
1
=

6
4
0
.
0
3
3
5
4
9
9
0
.
0
5
.
8
1
5
3
=

M
B

3 -2

50 mm

m
N
4
.
0
1
m
1
N
1
8
.
9
m3
N1
5.
6
8
1
-

Resultant bending moment at 3-2

is estimated as follows:

3-3

m
N
2
4
.
3
1
1
=

=
22
22
RR
M
B

75 mm

2 -2
3-3
3 -2
Bending Moment-Horizontal Plane.

22

6th. Step (Contd.) Shaft Design

53 mm

I d 4 / 64

and
y
d /2

Maximum bending stress at section 3-3:

P as

3 -2

2 -2

Layout

m
N
6
2
m
N
2
9
.
3
2

m
N
2
.
8
6

fc

3
3

3-3

50 mm

Bending Moment-Vertical Plane.

0
1

8
1

75 mm

m
N
4
.
0
1
m
1
N
1
8
.
9
m3
N1
5.
6
8
1
-

stress concentration factor ).

1.5 32 198.6

0.0553 3

79 mm

Myy
32 M
fc
fc
I
d3

(Section modulus

fc

d=50 mm

Maximum bending stress in any section of

rotating shaft (solid):

d=55.3 mm

Bending Stress and search for Critical Section (Contd)

is taken 1.5 for hob cut gear.

2 -2
3-3
3 -2
Bending Moment-Horizontal Plane.

23

6th. Step (Contd.) Shaft Design

L
Maximum bending stress at section 3-2:

d=50 mm

d=55.3 mm

Bending Stress and search for

Critical Section ((Contd))

79 mm

1.5 32 141.84

0.05 3

fc

2
3

0
1

4
3
.
7
1

P as

53 mm

75 mm

3-3

is taken 1.5 for well designed step.

3 -2

50 mm

2 -2

Layout

m
N
4
.
0
1
m
1
N
1
8
.
9
m3
N1
5.
6
8
1
-

Maximum bending stress at section 2-2:

P as

It is apparent that section 2-2 is critical.

m
N
6
2
m
N
2
9
.
3
2

is taken 2 for milled keyway.

keyway

Bending Moment-Vertical Plane.

m
N
2
.
8
6

fc

2
3

0
1

5
.
8
1

2 3 2 1 1 3 .4 2

0 .0 5 3

2 -2
3-3
3 -2
Bending Moment-Horizontal Plane.

24

6th. Step (Contd.) Shaft Design

Lastly: Verification of Overall factor of safety at Critical Section
As already mentioned earlier, in gear unit design the size of the gear shaft usually
biased by the sizes of gears, bearing layout and centre distances.
Particularly in case of shaft integral with the pinion there is little scope of predesigning the shaft.
In such cases maximum stresses in the shaft are estimated identifying critical sections.
sections
Then a factor of safety f s can be estimated using the following formula,
which is base on maximum shear stress theory under combined, bending,
torsion and direct normal stresses.

Sy

a 4 m2
m k f
fs
Sen

Sy
Where,

S y = Yield strength of shaft material

S en = Endurance strength
g of shaft material
m = Mean (average) stress at considered section due to axial load.

a =
m=
k

Maximum alternating stress at considered section due to bending.

Maximum shear stress at considered section due to torsion.

= A factor considering the feature of section and severity of service.

It is chosen considering on what basis a has been calculated.

25

6th. Step (Contd.) Shaft Design

S y = 600 MPa,

75 mm

3-3

finished /ground shaft),

fc

Pas

1 6T
16 148

d3
0 .0 5 3

Layout

Bending Moment-Vertical Plane.

m
N
6
2
m
N
2
9
.
3
2

2 -2

s
a
P
6
0
1

1
.
2
1

m fc

m
N
2
.
8
6

3 -2

50 mm

m
N
4
.
0
1
m
1
N
1
8
.
9
m3
N1
5.
6
8
1
-

Fa
673.5
2

d2
0.052

6
0
1

5
.
s 8
a 1
P
2
6
0
3
1
b

2
7
1
.
0

m fc

79 mm

53 mm

S en = 420 MPa (About 45% of Su for well

d=50 mm

In present design, the pinion is integral with

shaft therefore shaft material is EN19A.
Therefore, for the critical section 2-2:

d=55.3 mm

Verification of Overall factor of

safety
y at Critical Section ((Contd))

is taken 2 in general for milled single keyway.

keyway

2 -2
3-3
3 -2
Bending Moment-Horizontal Plane.

26

6th. Step (Contd.) Shaft Design

d=50 mm

Substituting values f S for the critical

section 2-2 is calculated as follows:

d=55.3 mm

Verification of Overall factor of

safety
y at Critical Section ((Contd))

79 mm

600 10
600

0.172 1.5
18.5 106 4 (12.1106 ) 2
420
fs

75 mm

3-3

3 -2

50 mm

2 -2

Layout

m
N
4
.
0
1
m
1
N
1
8
.
9
m3
N1
5.
6
8
1
-

46.6 106

53 mm

Therefore,

Usually
y

f s is taken as 2.5 to 3.

m
N
6
2
m
N
2
9
.
3
2

This is highly satisfactory.

Bending Moment-Vertical Plane.

m
N
2
.
8
6

600

46.6

7
8
.
2
1

fs

2 -2
3-3
3 -2
Bending Moment-Horizontal Plane.

27

6th. Step (Contd.) Shaft Design

Input Shaft
The Input Shaft is also integral with the 1st. stage pinion.
Therefore, the material is EN19A.
Shaft design verification is done in same way as it is done for intermediate shaft.

Output
p Shaft
The Output Shaft not integral with the gear.
Therefore, medium carbon steel (C40 or C45, Equivalent to EN8), having
ultimate strength- 560 MPa and yield strength- 280 Mpa, is taken as the
material.
The Shaft diameter is initially estimated
on transmitted torque as follows:

16To
do 3
S sa

To 1.5
1 5 31 39
39.1
1

m
N
8
1
8
1

In the present design considering a factor of 1.5 with nominal torque

the Output torque:

Nominal

do

m
m
5
6
.
3
5

Considering allowable shear stress ( S sa ) of material is 60 MPa.

Considering the end bearings of ID 55 mm (Say SKF Ball Bearing 6311) Shaft
design verification is done same way as is done for intermediate shaft.

28

Thank You

29