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Appropriate sizes for the housing of the gearbox is required so as a rough sketch of the gear box
may be created and hence to determine actual axial dimensions. The overall length as well as the
distance between the gears of the intermediate shafts is required so as to account for the fittings
and attachments which will be mounted to the shafts.
The diagram below (Figure 6.1) shows a layout of all three shafts accounting for the other
fittings to be mounted such as bearings. Since the gear widths have been determined, the bearing
widths may be estimated allowing for larger spaces for larger bearings on the intermediate shaft
where the bending moment shall be the maximum in the gearbox.
Small changes in bearing widths will have little to no effect on the force analysis of the gearbox
since the location of the reacting normal forces will only be altered by minuscule amounts. A
0.30 m allowance between the two gears on the countershaft is given. This is dictated by the
mounting requirements of the bearings as well as the spatial requirements of the input and output
shafts. Other small allowances have also been accounted for the retaining rings as well as the
protrusion behind the bearings.
Rough Layout :
The diagrams below have been used to conduct the force analysis on the gearbox system.
!
!
!
The general layout and axial dimensions of the countershaft onto which two spur gears shall be
mounted has been determined. The gears and bearings are supported by shoulders and held in
place by retaining rings. The gear transmits torque through the keys and keyways mechanism.
The Tangential and Radial forces transmitted from the gears to the shaft may be determined as
shown below in Figure 6.2.
t and r represent the Tangential and Radial directions respectively and 12 and 34 represent the
forces exerted on Gear 1 and Gear 4 as well as the force exerted on Gear 2 and Gear 3
respectively.
! y = 0;
ΣF
r r
! ay − W12
R − W34 + Rby = 0
! ay + Rby = 2.36 k N
R
! ΣMAz = 0;
−0.87
! × 80 − 1.49 × 380 + Rby(460) = 0
! by = 1.38 k N
R
! ΣMAy = 0;
2.39
! × 80 − 4.09 × 380 + Rbz(460) = 0
! bz = 2.96 k N
R
! ay + 1.38 k N = 2.36 k N
R
R
! ay = 0.98 k N
! ΣFz =0
! Az = − 1.26 k N = !1.26 k N
R
(2) ( 2 )
t
d2 280
T
! =W
! 12 = 2.39 × = 334.6 Nm
! ay = 0.98 k N
R ! az = 1.26 k N
R
! by = 1.38 k N
R ! bz = 2.96 k N
R
Shear Force Diagram and Bending Moment Diagrams
X-Y Plane:
A o V M
Ray
0 < x < 80
! ΣMo =0 ! y=0
ΣF
! ay(x) − M = 0
R ! ay − V = 0
R
! 0.98 (x) − M = 0 ! = 0.98 k N
V
! = 0.98 x
M
`!
! ΣMo =0 ! y=0
ΣF
r r
! ay(x) − W12
R (x − 80) − M = 0 ! ay − W12
R − V = 0
! = 0.11 x + 69.6
M
! ΣMo =0 ! y=0
ΣF
r r r r
! ay(x) − W12
R (x − 80) − W34 (x − 380) − M = 0 ! ay − W12
R − W34 −V =0
! = − 1.38 x + 635.8
M
X-Z Plane:
A o V M
Raz
0 < x < 80
! ΣMo =0 ! ΣFz =0
! az(x) − M = 0
R ! az − V = 0
R
! 1.26 (x) − M = 0 ! = 1.26 k N
V
! = 1.26 x
M
80 mm
A o V M
Raz
! ΣMo =0 ! ΣFz =0
t t
! az(x) − W12
R (x − 80) − M = 0 ! az − W12
R − V = 0
! = − 1.13x + 191.2
M
Wt12
80 mm 300 mm
A o V M
Raz Wt34
! ΣMo =0 ! ΣFz =0
t t t t
! az(x) − W12
R (x − 80) − W34 (x − 380) − M = 0 ! az − W12
R + W34 −V =0
1.26 (x)
! − 2.39 (x − 80) + 4.09 (x − 380) − M = 0 V
! = 2.96 k N
! = 2.96 x − 1363
M
The Shear Force diagrams and Bending Moment diagrams (Figure 6.4 and 6.5) for the shafts are
given in the next two pages.
334.6KNmm
Using the figures above, the total moment may be obtained by combining both planar torques as
vectors:
! total = 100.82 + 78.42 = 127.7 k Nmm
M
Moments at Point b and Point d may be given as follows:
! total,b = 109.22 + ( − 215.6)2 = 241.68 k Nmm
M
ka = 4.51 (470)-0.265
ka = 0.88
kf = 1+ q (kt – 1 )
kf = 1 + 0.77 (1.5 – 1 )
kf = 1.385
kfs= 1.57
Se:
Se = kakbkckdkekf S′e
Se = 194.11 MPa
Diameter of the Shaft at Point B may be calculated using the D-E Goodman equation and
assuming Safety Factor, n =1.5.
! !
d=
1
0.5 3
16 × 1.5 1 2 0.5 1
( ) ( )
2 2 2
(! { [4(1.385 × 241.68) + 3 1.57 × 0 ] + [4(1.385 × 0) + 3 1.57 × 334 ] })
π 194.11 × 106 470 × 106
D
Typical ! ratio for Support Shoulder is 1.2, hence, D = 1.2 × 35 = 42 mm.
d
A nominal diameter of 45 mm for the cold drawn shaft may be chosen to check whether the
previous estimate was suitable.
D 45
Hence, = = 1.29
d 35
d 35 r 3.5
Assuming the Fillet Radius , r = ! =! = 3.5 mm so ! = ! = 0.1
10 10 d 35
= 1+ 0.82( 1.4 – 1 )
= 1.328
Size Factor, kb = 1.24d-0.107 (2.79≤ d ≤ 51 mm) from Diagram 6-20.
kb = 1.24(35)-0.107 = 0.85
ka = 0.88 (Unchanged)
Se = kakbkckdkekf S′e
= 195.9 MPa
2 2
32k f Ma 16k fsTa
σa′ = [( ) + 3( ) ] where Ta = 0
πd 3 πd 3
2
32k f Ma 32(1.48)(241.68) 2
!= ( ) =! ( ) = 84.98 MPa
πd 3 π (0.035)3
2 2
32k f Mm 16k fsTm
σm′ = [( ) + 3( ) ] where Mm = 0
πd 3 πd 3
2
16k fsTm 16(1.328)(334.6) 2
!= 3( ) = ! 3( ) = 91.42 MPa
πd 3 π (0.035)3
The fatigue failure criteria for the modified Goodman Line may be given as follows:
1 σ ′ σ ′ 84.98 91.42
! = a + m != + = 0.63
nf Se Sut 195.9 470
n
! f = 1.59 (Almost similar to Goodman Fatigue Safety Factor of 1.5)
Checking the diameter at the end of the keyway, just to the right of Point b and at the groove of
Point d. From the moment diagram, Moment, M at the end is estimated as 245 Nm.
Assuming the radius at the bottom of the key way will be according to the standard:
Since r
= 0.02
d
kt = 2.14
kts = 3.0
q = 0.63
qs = 0.7
kf = 1+ q (kt – 1 )
= 1 + 0.63(2.14 – 1)
= 1.72
kf s= 1+ q (kts – 1 )
= 1 + 0.7(3 – 1)
=2.4
Se = kakbkckdkekf S′e
= 227.66 MPa
2 2
32k f Ma 16k fsTa
σa′ = [( ) + 3( ) ] where Ta = 0
πd 3 πd 3
2
32k f Ma 32(1.72)(245) 2
!= ( ) =! ( ) = 100.11 MPa
πd 3 π (0.035)3
2 2
32k f Mm 16k fsTm
σm′ = [( ) + 3( ) ] where Mm = 0
πd 3 πd 3
2
16k fsTm 16(2.4)(334.6) 2
!= 3( ) = ! 3( ) = 165.22 MPa
πd 3 π (0.035)3
n
! f = 1.23
The keyway hence turns out to be much more critical than shoulder. The diameter may be
increased or a higher strength material may be used.
Using 1050 Cold Drawn Steel with Sut = 690MPa
ka = 4.51 (690)-0.265
ka = 0.798
kt = 2.14
kts = 3.0
q = 0.7
qs = 0.76 kf = 1+ q (kt – 1 )
= 1 + 0.7(2.14 – 1)
= 1.798
kf s= 1+ q (kts – 1 )
= 1 + 0.76(3 – 1)
=2.52
Se = kakbkckdkekf S′e
= 215.81 MPa
2 2
32k f Ma 16k fsTa
σa′ = [( ) + 3( ) ] where Ta = 0
πd 3 πd 3
2
32k f Ma 32(1.798)(245) 2
!= ( ) =! ( ) = 104.65 MPa
πd 3 π (0.035)3
2 2
32k f Mm 16k fsTm
σm′ = [( ) + 3( ) ] where Mm = 0
πd 3 πd 3
16(2.52)(334.6)
2 2
16k fsTm
!= 3( ) = ! 3( ) = 173.48 MPa
πd 3 π (0.035)3
1 σ ′ σ ′ 104.65 173.48
! = a + m != + = 0.66
nf Se Sut 215.81 690
n
! f = 1.51
Since the Goodman Criteria is conservative, the safety factor is deemed as being close enough to
1.5.
From the Torque Diagram, note that no torque is present at the groove. From the Moment
Diagram, Ma = 197.65 Nm, Mm = Ta = Tm = 0.
= 234.79 MPa
Se 215.81
n
! f = =
σa 234.79
= 0.92
The safety factor is deemed as being to low. By referring to the website <www.globalspec.com>,
appropriate groove specifications for a retaining ring for a shaft diameter of 35 mm is given as
follows:
Width, a = 2 mm,
Depth, t = 1.5 mm
kt = 5.0
q = 0.62
kf = 1 + q(kt – 1)
= 1 + 0.5(5-1)
=3
32k f Mm
σ! a = !
πd 3
32(3)(197.66)
=!
π (0.035)3
= 140.88 MPa
Se 215.81
n
! f = = = 1.53
σa 140.88
At Point e, only bending is present and the moment is very small. However, the diameter is small
as well and the stress concentration factor is high for the sharp fillet required for a bearing. From
the Moment Diagram:
Ma = 42.52 MPa
q = 0.7
kt = 2.7
kf = 1 + 0.7(2.7 – 1)
= 2.19
32k f Mm
σ! a = !
πd 3
32(2.19)(42.52)
=!
π (0.025)3
= 60.7 MPa
Se 215.81
! f =
n = = 3.56
σa 60.7
With the diameters specified for the critical locations, trial values may be used for the rest of the
diameters, taking into account typical shoulder heights for bearing support.
Hence,
D1 = D7 = 25 mm
D2 = D 6 = 30 mm
D3 = D5 = 35 mm
D4 = 45 mm
The Bending Moment is much smaller on the left side of the shaft. Hence, D1, D2 and D3 could
be made smaller. Unless the weight of the gearbox is a critical factor, there is little to no
advantage in removing more material and the extra rigidity may be needed to keep deflections
small.