Machine Design –II

Gearbox Design
By
Bhavik Soneji
Department of Mechanical Engineering
Indus University
 Overview
• Introduction to Gearbox
• Function of transmission box (gear box) inautomobile
• Main components of a gearbox
• Working of a principle gearbox
• Laws of stepped regulation of speeds inmulti-speed
•gearbox
• Design procedure of gear box (sliding geartype)
• Structural Diagram
• Kinematic Diagram
• Raydiagram
• SpeedChart
• Example

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 What isGearbox?

• An automobile requires high torque when climbing hills and when

starting, even though they are performed at lowspeeds.

• On other hand, when running at high speeds on level roads, high torque is
not required because of momentum. So requirement of a device is occur,
which can change the vehicle’s torque and its speed according to road
condition or when thedriver need.

• This device is known as transmission box.

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 Introduction to
Gearbox
• Gearbox often referred as transmission is a unit that uses gears and gear
trains to provide speed and torque conversions from a rotating power
source to another device. Gearboxes are employed to convert input from a
high speed power sources to low speed(E.g. Lift, Cranes and Crushing
Machine) or into a many of speeds(Lathe, Milling Machine and
Automobiles).

• A gearbox that converts a high speed input into a single output it is called
a single stage gearbox. It usually usually has two gears andshafts.

• A gearbox that converts a high speed input into a number of different

speed output it is called a multi-speed gear box. Multi speed gear box has
more than two gears and shafts. A multi speed gearbox reduces the speed
in different stages.

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 Function of transmission box (gear box)in
automobile
• The transmission box which is also known as the gear box is the
second element of the power train in an automobile. It is used to
change the speed and torque of vehicle according to variety of road
and load condition. Transmission box change the engine speed into
torque when climbing hills and when the vehicle required.
Sometimes it is known as torque converter. Main functions of a gear
box is as follow:

1. Provide the torque needed to move the vehicle under a variety of

road and load conditions. It does this by changing the gear ratio
between the engine crankshaft and vehicle drive wheels.

2. Be shifted into reverse so the vehicle can move backward.

3. Be shifted into neutral for

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 Main components of agear box
• In any device two or more component works together
and fulfills the required function. In a transmission box
four components are required to fulfill itsFunction
nction.
unter shaft
Main shaft
Gears
Bearings

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 1. Countershaft:
• Counter shaft is a shaft which connects with the clutch shaft directly. It
contains the gear which connects it to the clutch shaft as well as the main
shaft. It may be run runs at the engine speed or at lower than engine
speed according to gearratio.

2. Main shaft:
• It is the shaft which runs at the vehicle speed. It carries power form the
counter shaft by use of gears and according to the gear ratio, it runs at
different speed and torque compares to counter shaft. One end of this
shaft is connects with the universal shaft.

3. Gears:
• Gears are used to transmit the power form one shaft to another. They are
most useful component of transmission box because the variation is
torque of counter shaft and main shaft is depend on the gear ratio.

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• The gear ratio is the ratio of the driven gear teeth to the driving gear
teeth. If gear ratio is large than one, the main shaft revolves at lower
speed than the counter shaft and the torque of the main shaft is
higher than the counter shaft. On other hand if the gear ratio is less
than one, than the main shaft revolves at higher speed than the
counter shaft and the torque of the main shaft is lower than the
counter shaft. A small car gear box contains four speed gear ratio
and one reverse gear ratio.

4. Bearings:
• Whenever the rotary motion, bearings are required to support the
revolving part and reduce the friction. In the gear box both counter
and main shaft are supported by the bearing.

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 Working of a principle gearbox
• In a gear box, the counter shaft is mashed to the clutch with a use of a
couple of gear. So the counter shaft is always in running condition. When
the counter shaft is bring in contact with the main shaft by use of meshing
gears, the main shaft start to rotate according to the gear ratio.
• When want to change the gear ratio, simply press the clutch pedal which
disconnect the counter shaft with engine and change connect the main
shaft with counter shaft by another gear ratio by use of gearshift lever.
• In an gear box, the gear teeth and other moving metal must not touch.
They must be continuously separated by a thin film of lubricant. This
prevents excessive wear and early failure. Therefor a gearbox runs
partially filled with lubricantoil.

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 Laws of stepped regulation of speeds in multi- speedgearbox

Arithmetic Progression

Geometric Progression

Harmonic Progression

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Sr.No Comparison Arithmetic Progression Geometric Harmonic Progression
Parameter Progression

1 Definition In arithmetic In geometric In harmonic

progression, the progression, the progression, the
difference between ratio of any two difference between
any two successive successive spindle reciprocal of anytwo
spindle speeds is speeds is constant. successive speeds is
constant. constant.

2 Zth Spindle 1
− −1
Speed = ∅= =
[1− −1 ]
( −1)

3 Good in High spindle speed High spindle speed Low spindle speed
range range range

4 Poor in Low spindle speed Low spindle speed High spindle speed
range range range
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 Design procedure of gear box (slidinggear type)

A. For designing a stepped drive

Following informations arenecessary
Highest output speed
Lowest output speed
Number of steps(Z)

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 B. Break up of speedsteps
o The number of steps (Z) should be so selected that it can be
broken into the multiples of 2 & 3. Thus, selected values of Z
are : 6,8,9,10,12,14,16 & 18.

C. Structuraldiagram
 It gives the information about
o Number of shafts in thespeed box
o Number of gears on eachshaft
o The order of changing transmission in individualgroups to
obtain the desiredspeed.
o Transmission range
o Group characteristics

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 Whiledrawing thestructural diagram,
following points should beconsidered

a) Number of gears on the last shaft should be as minimum as

possible.
b) The speed reduction between the spindle and preceding shaft
should be as maximum as possible.
c) Number of gears on any shaft should not be more than three. It
can be four in exceptionalcase.
d) = 1 is for least radial dimensions of gear box. This is
possible by making the axes of adjacent shafts coincident i.e., co
axial

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• =1 is possible when maximum
speed reductions equals the maximum speed
increase.

• But considering the importance of reduction

of axial dimensions of gear in machine tool
with a traversing spindle head, the above
point does not favour it, because small axial
dimensions of traversing units arecritical.

• Structural formula represented by the special

form of graphs is called asstructural diagram.
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 Method of drawing structural
diagrams
1. If n= no of transmission groups then draw(n+1) vertical lines at a
convenient distance. Here the first vertical line represents the
transmission from motor shaft, and the rest represents the
transmission group of speedbox.

2. Draw an any of horizontal lines intersecting the vertical lines at a

distance of log∅from each other. The number of horizontal lines
are equal to the number ofspeed steps(Z). The spacing between
the horizontal line should be equal so that interval between the
spindle speeds is content. In practice the distance between
adjacent horizontal lines is taken equal to ∅,but not log for
convenience.

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 Cont…

3. Draw a line joining the first shaft of known speed & the second
shaft for calculated input speed. The speed reduction betweenthe
first and second shaft is usually through belt derive.

4. From second shaft at the input speed point of diverging lines joining the
third shafts. The number of lines will be equal to the number of
transmission. The maximum spacing between the lines on third shaft, will
be according to the calculated transmission range between these two
shafts say∅1∅2∅4∅6......etc.

5. From the third shafts for all groups draw the diverging lines, having
maximum spacing on the fourth shaft as per calculated value of
transmission range of groups.

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 Speed chart
 The speed chart depicts the transmission ratios. The structural diagram
depicts only range ratio so speed chart must be plotted to depict the
transmission ratios

o Horizontal line corresponds to transmission ratio, i = 1. (no speed)

o Line inclined upwards corresponds to transmission ratio, I >1 (increase in
speed)
o Line inclined downwards corresponds to transmission ratio, i <1 (decrease
in speed)

 While plotting the speed chart it is desirable to have minimum

transmission ratio i.e maximum speed reduction in the last
transmission group. The remaining shafts run at relatively
higher speed and so subjected to lesstorques.
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 KinematicDiagram
• A kinematic layout is a
pictorial representation
of gearbox, describing
the arrangement of
gears.
• It provides information
like number of stages,
number of shafts used,
number of gear pairs
and its arrangement.

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 Raydiagram

• A ray diagram is a representation of structural formula. It provides

information such as speed in each stage, the transmission ratio in each
stage, The total number of speeds and its values.

• As seen in fig. (a) the maxi speed and minimum speed both are higher for
shaft. This requires smaller size of shafts due to reduced torque. But as
fig(b) the maximum speed and minimum speed both are lower which
requires lager size of shaft due to increased torque. The version indicated
in fig( c ) is the middle situation. One will definitely prefer the version(b) ,
but if the machine cost of shafts is not a criterion , then version(a) is
preferred.

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 Example
• Design a gear box for a head stock to give 16 speeds ranging
from 50 rpm to 1600 rpm. The power is supplied by an
electric motor of 10 kw, running at 1440 rpm, through a V-belt
drive with a speed reduction of 2:1

Find (I) No. of teeth on each gears.

(II) Percentage variation in speed.

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 Solution
1. Selection of standard speed
Nmax = 1600
Nmin =50
Z =16 1
−1
∅=
1
1600 16−1
∅=
50
= 1.259 ≈ 1.25

2. From ∅= 1.25, the standard speeds are

50, 63, 80, 100, 125,
160, 200, 250, 315, 400, 500, 630, 800, 1000, 1250, 1600 rpm

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 Cont…
3. Structural Diagram

here Z=16 = 2*2*2*2

P1=P2=P3=P4=2
here X1=1, X2=P1=2, X3=P1P2=4
X3=P1P2P3=8

∴ Structural Formula

Z= 2(1) 2(2) 2(4)2(8)

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 Z= 2(1) 2(2) 2(4) 2(8)

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 Cont…
4. Speed Chart

Here the power is supplied toinput shaft

through a belt
drive

Speed of input shaft

1440
= = = 720
2

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 Ray Diagram
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 1600
1250
1000
800
630
500
400
315
250
200
160
125
100
80
63
50

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 Cont…
5. Determination of number of teeth on gears
Between shaft 1 & 2
315 1 21 22 1
1 = = = = = ′
720 2.285 47.98 48 1

= 22 ′ = 48 ( +1 ′ = 70)
1 1 1

250 18 18 1 2
= = = = =
2
720 2.88 51.84 52 ′
2

= 18 ′ = 52
2 2

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 Cont…
• As the same like above,
Between shaft 2 & 3
=32 ′ = 25 ( 3+ ′ = 57)
3
3 3
=25 ′ = 32 ( 4+ ′ = 57)
4
4 4

• Between shaft 3 & 4

=32 ′ = 20 ( 5+ ′ = 52)
5
5 5
= 20 ′ = 32 ( 6+ ′ = 52)
6
6 6

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 Cont…
• Between shaft 4 & 5

• ′ = 20 ( 7+ ′
7 =50 = 70)
• 7 7

• ′ = 50 ( 8+ ′
8 = 20 = 70)
• 8 8

Schematic Representation of drive

• 6.

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 7. Percentage Variation in
Speeds
Sr Available Selecte %
N Speed (rpm) d Variation
o Speed

22 32 32 50
720∗ ∗ ∗ ∗ = 1689.6
1 48 25 20 20 1600 +5.06

18 32 32 50
720∗ ∗ ∗ ∗ = 1276
2 52 25 20 20 1250 +2.08

22 32 32 20
720∗ ∗ ∗ ∗ = 270.32
3 48 25 20 50 250 +8.12

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Sr Available Selected %

No Speed (rpm) Speed Variation

4 204.1 160 +2.05

5 1031.25 1000 +3.125

6 165 160 +3.125

7 778.84 800 -0.145

8 124.6 125 -0.32

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Sr Available Selected %

No Speed (rpm) Speed Variation

10 105.6 100 +5.6

11 498.46 500 -0.30

12 79.75 80 -0.31

13 402.83 400 +0.707

14 64.45 63 +2.30

15 304.2 315 -3.66

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 Cont…
8. Now the permissible speedvariation
is = 10 ∅− 1 %
= 10 [1.25-1]
= 2.5%
i.e. Maximum 5%variation

Here the percentage variation variation ismore

or less within
the permissible value.

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