PROJECT REPORT

On

DESIGN OF HELICAL GEARBOX

Submitted for partial fulfilment for the award of the degree

BACHELOR OF TECHNOLOGY
IN

MECHANICAL ENGINEERING
BY

PARTHA PRATIM PURKAIT

ARINDAM MONDAL
SUDIPTO MIDDYA
SUBHADEEP BANERJEE
Under the guidance of

PROF. SANJIB KUMAR CHAKRABARTY

(Assistant professor, Department of Mechanical Engineering, GMIT)

At

Department of Mechanical Engineering

GARGI MEMORIAL INSTITUTE OF TECHNOLOGY

BALARAMPUR, BARUIPUR, KOLKATA - 700144

 Certificate

Certified that this project report titled “HELICAL GEARBOX DESIGN” is the bonafide work of
“PARTHA PRATIM PURKAIT ( Reg No. – 132810110053)”, “ARINDAM MONDAL (Reg No. - )”,
“SUDIPTO MIDDYA (Reg No. - )”, “SUBHADEEP BANERJEE (Reg No. – 132810110063)” who
carried out the project work under my supervision as a Batch. Certified further, that to the best of my
knowledge. The work reported herein does not form any other project on the basis of which a degree or
award was conferred on earlier occasion for this or any other candidate.

Signature of the Head of the Department

( Prof. JYOTISH BASU)

Signature of the Project Guide

( Prof. SANJIB KUMAR CHAKRABARTY)

 ACKNOWLEDGEMENT

I express my heartiest gratitude first to my guide and my teacher Prof. SANJIB KUMAR
CHAKRABARTY for encouraging me to make this project. I would like to thank my all mechanical
department faculties with Head of the Department Prof. JYOTISH BASU.

Our Guide Prof. SANJIB KUMAR CHAKRABARTY who putting up with the perpetual project
experiment in our long goal. He always helps us when any time, any moment I need any suggestion
hand.
 ABSTRACT

The manuscript of the project provide a set of plans, calculations, basic operational parameters, various
design parameters, charge calculations and different costly information for making a gearbox.

The manuscript will also describe set of parameters several factors which affect operation, height,
diameter of gearbox, location of shafts, location of bearings.
 INTRODUCTION TO GEARBOX

An industrial gearbox is defined as a machine for the majority of drives requiring a reliable life and
factor of safety, and with the pitch line velocity of the gears limited to below 25 m/s, as opposed to mass
produced gearboxes designed for a specific duty and stressed to the limit, or used for very high speeds
etc., e.g. automobile, aerospace, marine gearboxes.

To the competent engineer, the design of a gear unit, like any other machine, may seem a fairly easy
task. However without experience in this field the designer cannot be expected to cover all aspects of
gearbox design.

The purpose of this booklet is to set out the basic design for an industrial gearbox. It should help
students not familiar with gearboxes, lay out a reliable working design. And it is intended for the reader
to use his own experience in selecting formulae, stress values etc., for gearbox components.
 WHAT IS EXTRUMAX

An EXTRUMAX is an extruder gearbox, single screw extruder continuously used in materials

processing technology require some specific features in designing of extruder gear reducer.

There are some advantages of using extruder gearbox. They are following:

Suitable to transmit the high torque for compressing and plasticizing moulding material and synthetics,
require for fibre line production.

Capability of absorbing the high thrust load induced by the process.

These are case hardened and ground double and triple stage parallel shaft design available in both
horizontal and vertical mounting.
 FEATURES OF EXTRUDER GEARBOX

 Modular concept of construction

 8 sizes of gearboxes convering ratio range 6.3:1 to 25:1
 The units are in split housing design
 The units are fully metric
 Solid input shaft with key
 Output bores with single keyway provision.
 ADVANTAGES OF EXTRUDER GEARBOX

 Compact design with optimum power density

 Long operating life
 Modular construction
 Interchangeability
 Less noise and vibration
 Ease to maintenance

COMPONENTS OF GEARBOX
 Gear and pinions: Helical gears and pinions are made from high quality alloy steel of case
hardened series for better case and core strength. Case hardened teeth profiles are ground to provide
efficient and quiet running. Softer core provides improved fatigue strength and surface ground gears to
high precision grade ensures high standard of accuracy and long wear life.

 Bearings : Shafts are supported by ample sized antifriction roller bearings of reputed
manufacturers. It is preferable to consider 294...E series thrust bearing.
The thrust bearing is of self aligning spherical roller type having capacity to carry
combined high thrust and radial load.

 Shafting: Input shaft is made from high quality case hardening alloy steel. Hollow output shaft is
made from direct hardening steel. Cylindrical seats for gears, bearings, seals and coupling are finished
by precision grinding.
Specific screw shaft requirement and fitment dimension must be stated during
placement of order.

 Gear Case: Torsionally rigid gearbox case made of high quality close grained cast iron and
having robust internal ribs to withstand high axial thrust.
Casing is in split design with optimal wall thickness, integral thrust bearing housing to
withstand high axial thrust load and for smooth running.
Casing designed with inspection cover for gearing check and oil filling. Fabricated
casing is available on request.

 Lubrication : The gears and bearings are splash lubricated. Cast oil trays are provided inside the
case to guide the churned lubricants towards the bearing. The thrust bearing housing shares the
lubrication with gearbox casing by some through holes.
The amount of lubricant in the chart is for reference. Use the oil level indicator for
correct filling.

 Cooling : Gearboxes are provided with cooling coil at the bottom of oil sump with water inlet and
outlet connections. Additional cooling systems can be supplied on request.

 Shaft Seals: Shafts are fitted with spring loaded high quality rubber oil seals to prevent outflow of
oil from gearbox and dust entry.

Designing
 Gear Shape or Pattern
The gear, which is used today is helical gear, which can take shock load, gear teeth always are
in contact with respective teeth, occupy less space and gear shifting is also noiseless.

 Material Selection
Materials for gear depend upon the duty type of load and the risk factor involved in the system.
For this project, the code of the chosen material is C45EN.
Tensile strength = 800MPa.
Ssy = (0.5×800) MPa or N/mm2 = 400 N/mm2
16 M t
τ=
Shear stress for the material, πd 3
 Working Machine : Profile Extruder Machine
 Actual extruder power : 100 KW
 Speed of Screw : 150rpm
 Ambient temperature : 30o C
 Surrounding : Indoor Space
 Altitude : Sea Level
 Driving Machine : Three phase A.C. Motor
 Motor Power : 180 KW
 Motor Speed : 1500 rpm
 Mounting Position : B3
 Output Shaft Details : Hollow
 Construction form : HR
 Speed Ratio : 25:1
 Output Centre Distance : 355 mm
 Input Shaft Diameter : 80 mm
 Helix Angle : 11o
 Pressure Angle : 20o

Calculations:
 2 πn 2 π×1500
= =157 . 07
Angular speed = 60 60 rad/sec.

180×1000 180×1000
= =1145. 98
Torque = ω 157 . 07 N-m

Normal module 5
= =5 .0935≈5
mn = transverse module = Cos ( Helix angle ) cos11

For the input centre distance of 250 mm,

( z p + z g )×mn
Centre Distance = 2 cos 11

To keep this centre distance constant we have chosen the number of teeth of the pinions and gears.

The number of teeth of pinion and gear of the stage 1 are zp =16 and zg = 83 respectively.

The number of teeth of pinion and gear of the stage 2 are zp = 19 and zg = 97 respectively.

In stage 1,

z p mn 16×5
= =81. 5
The pitch circle diameter of the pinion = cosψ cos11 mm.

zp
The root diameter of the pinion =
mn [ cos ψ ] [
−2 .5 =5
16
cos 11 ]
−2 .5 =69
mm.

zp
The addendum circle diameter of the pinion =
mn [ cos ψ ] [
+2 =5
16
cos 11 ]
+2 =91. 5
mm.

z g mn 83×5
= =422 .76
The pitch circle diameter of the gear = cosψ cos11 mm.

zg
The root diameter of the gear =
mn [ cosψ ] [
−2 .5 =5
83
cos 11 ]
−2 .5 = 410. 26
mm.

In stage 2,
 19×5 z p mn
=96 . 77
The pitch circle diameter of the pinion = cosψ = cos11 mm.

zp
The root diameter of the pinion =
mn [ cosψ
−2 .5 ] [
=
5
19
cos11 ]
−2 .5 =84 . 27 mm
.

z g mn
5×97
=494 .07 mm
The pitch circle diameter of the gear = cosψ = cos11 .

zg
The root diameter of the gear =
mn [ cosψ
−2 .5 ] [ =
5
97
cos11 ]
−2 .5 =481. 57 mm
.

Now, we have to calculate all the shaft diameters.

Here given that the input shaft diameter is 80 mm.

Now in case of intermediate shaft the produced torque is =

(5×1145916) N−mm=5729580 N−mm

So to get the intermediate shaft diameter

16 M t
τ=
πd 3
We know,

16 M t 16×5729580
d 3= = =72950 mm 3
τπ 400×π
3
d= √72950=130 mm
From this,

Hollow Output shaft diameter,

Similarly from the same equation we obtain,

Output shaft inner diameter = 190 mm

Output shaft outer diameter = 260 mm.

Bearing selection:

As the input shaft diameter is 80 mm the input shaft bearing specification is following:

Bearing number = 33216

Bearing inner diameter = 80 mm

Bearing outer diameter = 140 mm

Bearing width = 46 mm

Now as the intermediate shaft diameter is 130 mm, the bearing specification for the intermediate

shaft is following:

Bearing number = 32026

Bearing inner diameter = 130 mm

Bearing outer diameter = 200 mm

Bearing width = 45 mm.

The output shaft inner diameter is 190 mm. So the bearing specification is as follows:

Bearing number = 23940

Bearing inner diameter = 200 mm

Bearing outer diameter = 280 mm

Bearing width = 60 mm.

There is another thrust bearing for the outer diameter of the output shaft. As the outer diameter of the

output shaft is 260 mm, the thrust bearing specification is following:

Thrust bearing number = 29452

Thrust bearing inner diameter =

Thrust bearing outer diameter =

Thrust bearing width =

As per the calculation we have had all the parameters known to get the gearbox layout.
Here is the layout: