JIMMA UNIVERSITY

JIMMA INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL ENGINEERING
TITLE: “DESIGN OF NINE SPEED GEARBOX”
MACHINERY DESIGN GROUP PROJECT
YEAR/SEM. : V/I
GROUP MEMBERS ID No.
1 DEREJE MERGA RU 1343/10
2 KENASA DESTA RU 1763/10
3 MIHRET DEREJE RU 1921/10
4 LALISA DEREJE RU 1809/10
5 EFRATA TADELE RT 0092/10
6 YORDANOS LULU RU 2429/10
7 YEABSIRA MULAT RU 2388/10
8 SAMRAWIT GIRMA RU 2142/10
9 FETIYA ALIYI RU 1485/10
10 OBSE GEDEFA RU 2068/10
11 REDIET SILESHI RU 2086/10
12 LEMMA ZEWDIE RU 1813/10
13 Wondirad Takele RU 2364/10

Submitted to: Mr. Yahya A. (PhD candidates)

Submission Date: February 05/ 2022
 Design of nine speed gearbox for grinding machine

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 Design of nine speed gearbox for grinding machine

Abstract
In this project paper the nine speed gearbox assembly and its housing are designed with all
components and respective dimensions for grinding machines. A gearbox is a mechanical
device that is used to provide Speed and Torque conversions from a rotating power source to
output shaft. As the speed of the shaft increases, the torque transmitted decreases and vice versa.
Multi-speed gearboxes are used in applications which require frequent changes to the
speed/torque at the output shaft. Gearboxes work on the principle of meshing of teeth, which
result in the transmission of motion and power from the input source to the output.

The main objective of gear is to protect and to provide a safe platform to get good gear
transmission. It is also gives a supports for moving parts and protected it from outside condition.
The differential couples and the propeller shaft on the pinion, which is runs on the ring gear or
crown gear of the differential & it is also helps as the reduction in gearing friction. And enhance
the life of the gear. This can be most important tool in designing the differential gear housing
free from fatigue failures caused by the resonance. The design of the gear housing should be
appropriate a methodology for allocated with factors causing vibrations and to promote
scientific means and use to hold all components of the gearbox. The modeling of differential
gear box is done by using of SOLIDWORKS, for equation mathtype and for graph wonder share
edrawmax softwares. Finally, result for all components or parts is discussed based on the result
obtained in the analysis with their respective dimensions. For extra explanation, drafting of main
components of the gearbox are stated briefly with their drawings.

Key words: Gearbox, mathtype, Wonder share edrawmax.

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 Design of nine speed gearbox for grinding machine

Table of contents
Contents
Abstract ................................................................................................................................................................ ii

Table of contents ................................................................................................................................................. iii

List of figures ...................................................................................................................................................... iv

List of Tables ...................................................................................................................................................... iv

Chapter One ......................................................................................................................................................... 1

1 Introduction ....................................................................................................................................................... 1

1.2 Objectives .................................................................................................................................................. 3

1.2.1 General objectives ............................................................................................................................... 3

1.2.2 Specific objectives .............................................................................................................................. 3

1.3 significance .................................................................................................................................................... 3

1.4 Methodology .................................................................................................................................................. 4

1.5 Scope and limitations of the project........................................................................................................... 4

1.5.1 Scope of the project ............................................................................................................................ 4

1.5.2 limitations ........................................................................................................................................... 4

Chapter 2 .............................................................................................................................................................. 5

Literature Review................................................................................................................................................. 5

3 Design Analysis ................................................................................................................................................ 1

3.1 Design of gears .......................................................................................................................................... 1

3.1.1 Spur gear material selection ................................................................................................................ 1

3.2 gear calculation ...................................................................................................................................... 2

3.3 Design of shafts........................................................................................................................................ 16

3.3 Design of key for shafts ........................................................................................................................... 19

3.4 Design of bearings ................................................................................................................................... 24

3.4.1 Ball bearing calculation .................................................................................................................... 24

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 Design of nine speed gearbox for grinding machine
3.4.2 Needle Roller Bearing for Output Shaft Gear Wheels ...................................................................... 26

3.5 Gear housing ............................................................................................................................................ 27

4 Result and discussion ...................................................................................................................................... 28

Conclusion ......................................................................................................................................................... 29

References .......................................................................................................................................................... 30

Appendix ............................................................................................................................................................ 31

List of figures
Figure 1.1: Schematic representation of methodology ........................................................................................ 4
Figure 3.1: structural diagram .............................................................................................................................. 7
Figure 3.2 Initial ray diagram .............................................................................................................................. 8
Figure 3:3 Ray diagram for stage II ..................................................................................................................... 9
Figure 3.4 Complete ray diagram for nine speed gearbox ................................................................................. 10
Figure 3.5: kinematic arrangement .................................................................................................................... 11
Figure 3.6 : output shaft ..................................................................................................................................... 18
Figure 3.7: input shaft ........................................................................................................................................ 18
Figure 3.8: Intermediate shaft ............................................................................................................................ 19
Figure 3.9: key for output shaft.......................................................................................................................... 22
Figure 3.10 key for input shaft ........................................................................................................................... 23
Figure 3.11 key for intermediate shaft ............................................................................................................... 24
Figure ; drafting for all components .................................................................................................................. 37
List of Tables

Table 3:1 PSG 7.20 R-series ................................................................................................................................ 2

Table 3.2: Diameter of gears .............................................................................................................................. 15
Table 3.3 Calculation for standard spur gear ..................................................................................................... 16
Table 3.4 : Proportions of standard parallel keys .............................................................................................. 20
Table 3.5: summary of keys dimensions............................................................................................................ 24
Table 3.6: Basic static and dynamic capacities of various types of radial ball bearings ................................... 25
Table 4.1: result and discussion for all components .......................................................................................... 28

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 Design of nine speed gearbox for grinding machine

Chapter One
1 Introduction
Overview of gearbox
In mechanical Engineering applications, mostly the power is transmitted with the help of gears. There is a wide
range of gears for various applications such as very minute gears for wristwatches and there are also very large
gears that are used in ships, trucks, and the equipment used for mining. In many pieces of machinery such as
automobiles, washing machines, blenders, construction equipment, fuel pump, mills, mining engines, etc.; gears
are a vital element of mechanism. Toothed headgears are used to change the direction, speed, and power
between input and output shaft. When you see the inner construction of the gearbox, you will observe that it is
very simple. It consists of two gears coupled with each other mounted on two different shafts. The gear may be
spur, bevel, worm or helical. For gear reduction the diameter of input gear must be smaller than the diameter of
the output gear. If an only change in direction is required then the size of the gear may be the same. Spur gears
are used for heavy load applications, but they are noisy in operation. Due to gradual engagement, helical gears
are used silent in operation. Hence, they are used for light-load applications. If a change of plane of rotation is
required, then hypoid gears are used. (1)

In the power transmission system, the controlled application of power is provided by the transmission
mechanism. Transmission refers to the gearbox, which is used to provide speed and torque conversion from a
rotating power source to another device with the help of gear and gear trains. In automobiles the output of the
internal combustion engine is provided to the drive wheel with the help of a transmission mechanism. Such an
engine needs to operate at relatively high speed which is not appropriate for starting, stopping, and slow travel.
By increasing the torque, the gearbox reduces the higher engine speed to lower engine wheel speed. Also on
pedal bicycles, large machines, and where different speed and torque are required, transmissions are used. (2)

The source of rotary motion having higher angular momentum and lower torque is converted into higher torque
with the help of gears. This high torque is necessary for the performance of the work. This phenomenon of
increasing torque is called gear reduction which is brought by coupling of large gear called gear with small gear
called the pinion. This means, the speed of output shaft of the gearbox is less than the speed of input shaft of
the gearbox, and this reduction results in mechanical advantage i.e. increase in torque, which results in a
reduction of torque at the cost of angular momentum. This type of gearbox is called a reducer. The gearbox can
be structure to act as the exact opposite such as to give a large speed with a decrease of torque. Some of the

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 Design of nine speed gearbox for grinding machine
simplest gearboxes merely change the physical rotational direction of power transmission. Another use of
gearbox is to change the axis of the rotary motion of a plane with or without gear reduction.
Generally, gearboxes are used to increase the torque while reducing the speed of any motor or an engine. This
means that the output shaft of a gearbox rotates at a slower rate than the input shaft, and this reduction in speed
produces a mechanical advantage, increasing torque. And also, it increases the controllability that we have
options to shift according to the required condition.
Classification of the Gearboxes
In present days there are many kinds of gear arrangements. Basically, there are two types based of shifting
mechanism,
❖ Manual Shifting Gearboxes
❖ Automatic Shifting Gearboxes

We designed a constant mesh gearbox which is a Special category of manual gearboxes, Constant mesh gearbox
means all the gears are always in mesh and the engagement between the gears which are freely rotating on the
transmission main shaft and the transmission main shaft is affected by moving the dog clutches.
Types of Gears
There are many types of gear wheels such as,
➢ Spur Gears
➢ Helical Gears
➢ Bevel Gears
➢ Worm and gear set
➢ Rack and Pinion

In this gearbox designing project, all the gear wheels are spur gears.
Spur Gears
Spur gear are gears with teeth that project outwards from a cylindrical surface. Two spur gears are used to
transmit power between parallel shafts. A gear is a toothed wheel that engages another toothed mechanism to
change speed or the direction of transmitted motion. Gears are generally used for one of four different reasons:
1. To increase or decrease the speed of rotation;
2. To change the amount of force or torque;
3. To move rotational motion to a different axis (i.e., parallel, right angles, rotating, linear etc.);
4. To reverse the direction of rotation.

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 Design of nine speed gearbox for grinding machine
Spur gears are used to transmit power between two parallel shafts. The teeth on these gears are cut straight and
are parallel to the shafts to which they are attached.

Advantages of Spur Gears

• Spur gears have high power transmission efficiency.
• Compact and easy to install.
• Offer constant velocity ratio.
• Highly reliable.
• Can be used to transmit large amount of power
• Simplest and most economical type of gear to manufacture.

1.2 Objectives
1.2.1 General objectives
The main objective of this project is to design of nine speed gear-box for grinding machine with different
speed.
1.2.2 Specific objectives
The specific objectives of this project are:
• To design gear wheel within given speed range
• To design shafts
• To design spur gears in mesh
• To design key and to select bearing
• Design of housing
• To draw the main components using solidworks soft wares,

1.3 significance
The main significance of the study is:

• Depending on the purpose we can use different speed gear box

• Using 9 speed grinding gear box to mill surface of materials with required speed
• Can carry maximum stresses and deformation under the safety zone

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 Design of nine speed gearbox for grinding machine
1.4 Methodology

Figure 1.1: Schematic representation of methodology

1.5 Scope and limitations of the project

1.5.1 Scope of the project

The scope of designed gear box is that it is used only for grinding purpose. It does not include any other form
of application like milling, drilling, and heavy industries which use huge gear box for different application.

1.5.2 limitations
❖ Lot of projects hinder us to do deep design of gear box.
❖ The project can be Improved more if it manufactured but we can not get opportunity to develop its
prototype.
❖ To do simulation and analysis of mechanical properties like shear stress, bending moment, inertia and
other the knowledge we have for ansys software ban us.

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 Design of nine speed gearbox for grinding machine
Chapter 2
Literature Review
“The gearbox has variously used in agricultural, industrial, constructional, mining, and automotive equipment,
etc. and to maximize its efficiency gearbox with 8-speed variation is used. The highly effective 9-speed gearbox
has many benefits. The most important benefit is an increase in fuel efficiency. Another benefit is a fast-locking
torque converter that allows for quick engagement and limited-slip. This results in less wear and tear on the
clutches inside the unit and longer life. An additional benefit is that it provides smooth
shifts that happen so quickly that they often sensed by the driver. In Automobiles, the gearbox is mainly used
to supply. The gearbox has variously used in agricultural, industrial, constructional, mining, and automotive
equipment, etc. and to maximize its efficiency gearbox with 8-speed variation is used. The highly effective 9-
speed gearbox has many benefits. The most important benefit is an increase in fuel efficiency. Another benefit
is a fast locking torque converter that allows for quick engagement and limited-slip. This results in less wear
and tear on the clutches inside the unit and longer life. An additional benefit is that it provides smooth
shifts that happen so quickly that they often sensed by the driver. In Automobiles, the gearbox is mainly used
to supply.” (2)

Heavy vehicle transmission systems are subjected to noise and vibration under excitation condition. Internal
excitation forces, meshing forces, load and speed variation and gear defects are one of the major sources of
excitation. Automobile differential gearbox is an assembly of gears to meet the torque variation for dividing the
speed of the wheel on turning conditions. The speed at the input shaft is maximum which is minimize at output
shaft to increase torque value. High value of torque is transmitted to drive shaft. Noise and vibration reduction
in heavy vehicle transmission system is a constant development, because noise and vibration are the two reasons
for transmission failure. Mechanical properties of material influence the vibration signature pattern. The
simulation results show that natural frequencies and mode shapes show different characteristics as we change
the materials. Grey cast iron have damping property to reduce the vibration effect so it is used as automobile
casing materials but structural steel have high density, it is used as casing material for heavy static machinery
in industrial application. (3)

Gears and gear drives have been known and used for millennia as critical components of mechanisms and
machines. Over the last several decades the development of gearing has mostly focused in the following fields:
the improving of material, manufacturing technology and tooling, thermal treatment, tooth surface engineering
and coatings, tribology and lubricants, testing technology and diagnostics. Gear design is a highly complicated
art. The constant pressure to build less expensive, quieter running, lighter, and more powerful machinery has

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 Design of nine speed gearbox for grinding machine
resulted in a steady change in gear designs. At present much is known about gear load-carrying capacity, and
many complicated processes for making gears are available. Gear design also included material selection, which
should provide the required strength and durability of every component in the gear drive. The vast majority of
gears are designed with the standard 20⁰ pressure angle tooth proportions. (4)

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 Design of nine speed gearbox for grinding machine
3 Design Analysis

Given specifications
Nine speed gearboxes for grinding machine
Minimum speed= nmin = 100rpm

Maximum speed= nmax = 700rpm

Motor speed = nm = 1400rpm

3.1 Design of gears

3.1.1 Spur gear material selection
Some factors are to be considered while choosing the gear material. The main three factors are strength,
durability, and cost. The cost includes the cost of the material and the cost of manufacturing. The importance
of these factors is different for different projects. The main factor of material selection for gear is getting the
correct combination of physical properties that fulfill the requirements of the gearbox at a low cost. Gears can
be manufactured of various materials used for gear making, some of them are steel, brass, bronze, cast iron,
ductile iron, aluminum, powdered metals, and plastics. But the Steel is the most commonly used material for
gearbox manufacturing. Mostly steel is used for making gear because of advantages such as high resistance to
wear and the ability to increase the physical properties by the use of various heat treatment.
Material for pinion:
‘15 Ni 2 Cr 1 Mo 15’
Bending stress = 3200 kgf/cm2
Crushing stress = 9500 kgf/cm2
Material for gear:
‘15 Ni 2 Cr 1 Mo 15'
Bending stress = 1400 kgf/cm2
Crushing stress = 5000 kgf/cm
40 Ni 2 Cr 1 Mo 28…Nickel chromium molybdenum steel (5)

Properties of Gear Wheel Materials

• High tensile strength to prevent failure against static loads.
• High endurance strength to withstand dynamic loads.
• Low coefficient of friction.
• Good manufacturability.

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 Design of nine speed gearbox for grinding machine
3.2 gear calculation
Method-I
Step1: Calculate range ratio and speed steps
Progression ratio= 
1
 n  z −1
 =  max  where z = number of speed of gear box= 9
 nmin 
1 1
 700  9−1  7 8
 =  =   => 1.275  = 1.275 is not standard value
 100  1
Note :- Ratio of any two successive spindle speed is constant, that is
n1
=  = progression ratio, n1 = nmin = 100rpm
n2

n1 = 100rpm
n2 =   n1 = 1.275 100 = 127.5rpm  128rpm
n3 =   n2 = 1.275 127.5 = 162.5625rpm  164rpm
n4 =   n3 = 1.275 162.5625 = 207.2672rpm  208rpm
n5 =   n4 = 1.275  207.2672 = 264.266rpm  264rpm
n6 =   n5 = 1.275  264.266 = 336.938rpm  338rpm
n7 =   n6 = 1.275  336.938 = 429.597 rpm  430rpm
n8 =   n7 = 1.275  429.597 = 547.736rpm  548rpm
n9 =   n8 = 1.275  547.736 = 698.36rpm  700rpm

Therefore, speed steps are :- 100,128,164,208,264,338,430,548, and 700 rpm

Method-II Using PSG series for range ratio
 = 1.275 is not standard value.
BASIC SERIES OF PREFERED NUMBER
Table 3:1 PSG 7.20 R-series

R5 R10 R20 R40

 = 1.60  = 1.25  = 1.12  = 1.06
1.00 1.00 1.00 1.00
1.06
1.12 1.12

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 Design of nine speed gearbox for grinding machine
1.18
1.25 1.25 1.25
1.32
1.40 1.40
1.50
1.60 1.60 1.60 1.60
1.70
1.80 1.80
1.90
2.00 2.00 2.00
2.12
2.24 2.24
2.36
2.50 2.50 2.50 2.50
2.65
2.80 2.80
3.00
3.15 3.15 3.15
3.35
3.55 3.55
3.75
4.00 4.00 4.00 4.00
4.25
4.50 4.50
4.75
5.00 5.00 5.00
5.30
5.60 5.60
6.00
6.30 6.30 6.30 6.30

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 Design of nine speed gearbox for grinding machine
6.70
7.10 7.10
7.50
8.00 8.00
8.50
9.00 9.00
9.50
10 10 10 10

R5 and R10 series cannot be used, because 1.6  1.275 ,

product of R10 series also greater than calculated value. so, R10 series will not be used
1.25 1.25 = 1.5625  1.275 .
Check product of R20 and R40 series to select appropriate speed for the design.
Product of R20 series is
1.12 1.12 = 1.2544  1.275
Product of R40 series is
1.06*1.06 = 1.1236  
1.06*1.06*1.06 = 1.191  
1.06*1.06*1.06*1.06 = 1.2624    1.275
product of R40 series is suitable to get speed steps for our design but, the maximum output speed is beyond our
desire. So, the preferable R series is R20 in order to get nearest value given for designing nine speed gearbox.
By multiplying the last value of R20 series with 10 the obtained value is 100rpm which is our minimum speed.
by skipping one progression ration the next speed is selected.
Example
10*10 = 100rpm
1.00 = escape
1.12*100 = 112rpm
1.25 = escape
1.4*100 = 140rpm...
Therefore, the speed steps obtained by using R20 series are 112,140,180, 224, 280,355, 450,560 and 710 rpm
From the above two methods, the first method preferred over second method. Because it fulfills the given
specification. Since 710rpm is greater than the given maximum speed, which is 700rpm.

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 Design of nine speed gearbox for grinding machine
Step 2 :- calculate number of stages and number of shafts

9 Use factor of nine except one to

get number of stages

3 3

Or use logarithmic function of base 10

log10z
Nos = z= speed, p=factor of speed and Nos = number of stages
log10p
9
log10 ln 9
Nos = 3
= =2
log10 ln 3
Therefore, number of stages are two.
No. shafts = No. stages + 1 = 2 + 1 = 3 .

Step 3:- determination of structural formula

Z = P1 ( x1) P 2 ( x 2)
P1 = 3
P2 = 3 z = 9

P1 p2 3 * 3

Feasibility of structural formula and diagram

x1 = input  1

x2 = Speed step corresponding to x1

Z = P1 ( x1) P 2 ( x 2 ) .................................(1)
Z = P2 ( x1) P1 ( x 2 ) ..................................( 2)

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 Design of nine speed gearbox for grinding machine
x1  x2 .......................1st Feasibility conditions
b  8
Z = P1 ( x1) P 2 ( x 2 )

3 (1) 3 ( 3) ........................ ( 3)

Z '' = P 2 ( x1) P1 ( x 2 )

3 (1) 3 ( 3) .........................( 4)

Since, structural formula in equation ( 3) & ( 4 ) are the same, the optimum structural formula for nine speed

gearbox is 3 (1) 3 ( 3) .........................( 5)

Step 4: Structural diagram (speed diagram)

Corresponding to optimum structure diagram

Z = 3 (1) 3 ( 3)

n9 = 700rpm
n8 = 548rpm
n7 = 430rpm
n6 = 338rpm
n5 = 264rpm
n4 = 208rpm
n3 = 164rpm
n2 = 128rpm
n1 = 100rpm

Draw structure diagram for only optimum structure formula.

Procedure to construct speed diagram:
1. No. of vertical line- N + 2 where, N is number of stages = 2
= 2+2 = 4
2. No. of Horizontal line –if nmax  nem , then the answer is z

If nmax  nem , then the answer is z + 1

nmax = 700rpm  nem = 1400rpm ,

No. of Horizontal line = z + 1 = 9 + 1 =10

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 Design of nine speed gearbox for grinding machine
3. Draw node point of p1 , p2 , ……………., pn on 2nd ,3rd ,……..., N + 1 line respectively.

4. Draw transmission lines in diagram.

Figure 3.1: structural diagram

x1  x 2
Feasibility study
b  8
b=6
b = distance between two extreme line originating from single

b  8

(1.275)
6
8
……… …. .Feasibility diagram
4.295  8

Step 5: Ray diagram

z = 3(1) 3(3) …………………….. sub step 1=sub step 2

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 Design of nine speed gearbox for grinding machine
The vertical line indicates shafts of gearbox.
The horizontal lines are the number of steps in structural diagram

Figure 3.2 Initial ray diagram

Stage II
Selection criteria to determine input speed
1, The input speed should be greater than half the speed steps.
nmax
2, 2
ninput

nmin 1
3, 
ninput 4

Where, nmax => maximum speed for stage 2

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 Design of nine speed gearbox for grinding machine
ninput => input speed for stage 2

430

208
264
8
100

 nmin 100 
n = = 0.38  0.25
 input 264 
  Both required conditions are satisfied
 nmax = 430 = 1.628  2 
 ninput 264 

Figure 3:3 Ray diagram for stage II

Stage-I
For the first stage possible input speeds are 548 and 700rpm, since the input speed should be greater than half
of the speed steps.

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 Design of nine speed gearbox for grinding machine
For the second condition,

43
0
548 338

264

 nmin 264 
n = = 0.4817  0.25
 input 548 
  Both conditions satisfied.
 nmax = 430 = 0.7846  2 
 ninput 548 

Figure 3.4 Complete ray diagram for nine speed gearbox

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 Design of nine speed gearbox for grinding machine
Step 6 :-Gearing diagram (kinematic arrangement)

Optimum structural formula

3 (1) 3 (1)

Stage 1=3
Stage 2=3
Total gear 6 pairs =12 gears

Figure 3.5: kinematic arrangement

Step 7 :- Number of teeth on gears

Stage -1

Zi= number of teeth input gear

Zo= number of teeth on output gear

Stage-2

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 Design of nine speed gearbox for grinding machine

Assume minimum number of teeth on the smaller gear is 20= z11

Z11 N12 100 20

Z11 = 20 → = = =
Z12 N11 264 Z12
20* 264
Z12 = = 52.80 53
100
Z12 = 53

Second pair speed reduced from 264rpm to 208rpm

z7 n8 z 208
= → 7 = = 0.7878
z8 n7 z8 264
z7 = 0.7878 * z8
z7 + z8 = z11 + z12 = 20 + 53 = 73
73
z7 + z8 = 0.7878 * z8 + z8 = 1.7878 * z8 = 73 → z8 = = 40.83  41
1.7878
z7 = 0.7878 * z8 = 0.7878 * 41 = 32.303
z7  32

3.Third pair ,speed is increased from 264rpm to 430rpm.

z9 n 430
= 10 = = 1.6287878
z10 n9 264
z9 = 1.6287878 * z10

z9 + z10 = z11 + z12 = z7 + z8 = 1.6287878 * z10 + z10

2.6287878 * z10 = 73
73
z10 = = 27.77  28
2.6287878
z10 = 28
z9 = 1.6287878 ( 28 ) = 45.6060  46
z9 = 46

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 Design of nine speed gearbox for grinding machine
Stage 2

430

548 338

264

a. first pair : speed reduced from 548rpm to 264 rpm.

Assume minimum number of teeth on the smaller gear for stage1 is 18 teeth number.

z5 N 6 18 264
z5 = 18  = = = = 0.48175
z6 N5 z6 548
18
= 0.48175  z6 = 38
z6

b. second pair : reduced from 548rpm to 338 rpm

z1 N1 338
= = = 0.61678
z2 N 2 548
z1 = 0.61678 * z2
z1 + z2 = z5 + z6 = 18 + 38 = 56
0.61678 * z2 + z2 = 1.61678 z2
z2 = 34.6  35, z2 = 35
z1 = 0.61678 * z2 = 0.61678 * 35 = 22
c. third pair :speed reduced from 548rpm to 430rpm
z3 N 4 430
= =  z3 = 0.78467 * z4
z4 N 3 548
z1 + z2 = z3 + z4 = z5 + z6 = 77
z1 + z2 = 0.78467 * z4 + z4 = 77
1.78467 * z4 = 77
z4 = 43.145  44
z4 = 44, z3 = 33

Therefore, teeth numbers on all gears are: 22,35,33, 44,18,38,32, 41, 46, 28, 20,53

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 Design of nine speed gearbox for grinding machine
Step 8:- calculation of module, m.

pc b
Module= m = ,  m = ………………………………………….(6)
4 * M m

Where, pc= circumferential force

M= Material constant

=80- for 15Ni2cr1Mo15 ,PSG 8.32

b= face width, mm

T12= torque , Nmm

r12= radius of 12th gear

n12= speed of 12th gear

=100rpm

T12
pc =
r12
2 n12T
power = p = , Assume = p = 2 KW = 2 *103 W
60
2 *100 * T 2 *103 * 60
2 *103 = T = Nm
60 200
T = 190.988 Nm = 190.988 *103 Nmm …………………..(7)
d12 m * z12
r12 = = , d12 = m * z12
2 2
m * z12
r12 =
2
T 190.986 *103 Nmm * 2
pc =  pc = , z12 = 53
r12 m * z12

381.972 *103 Nmm 7.207 *103 Nmm 7207 Nmm

pc = = =
m * 53 m m
7207 Nmm
pc = ..................................... (1)
m

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 Design of nine speed gearbox for grinding machine
b
From PSG data book m = ,assume  =10
m
b
m = = 10
m
M= Material constant for 15Ni2cr1Mo15=80…………………………….PSG 8.32
7207
pc m = 7207
m =
2
=
m * m 10 *80 800m
7207 7207
m2 =  m3 = = 9.00875
800m 800
m = 2.08075mm
The standard value from PSG data book 8.2
m = 2.5mm
Step; calculation of diameter of gear
Module =2.5mm
Numbers of teeth on all gears are 22,35,33, 44,18,38,32, 41, 46, 28, 20,53
diameter d
m= =  d = m* z
teeth z
Table 3.2: Diameter of gears
Gear Z(teeth) d=m*z d(mm)
1 22 2.5*22=55 55
2 35 2.5*35=87.5=88 88
3 33 2.5*33=82.5=83 83
4 44 2.5*44=110 110
5 18 2.5*18=45 45
6 38 2.5*38=95 95
7 32 2.5*32=80 80
8 41 2.5*41=102.5=103 103
9 46 2.5*46=115 115
10 28 2.5*28=70 70
11 20 2.5*20=50 50
12 53 2.5*53=132.5=133 133

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 Design of nine speed gearbox for grinding machine
Step 9 : calculation of center distance

 Z + Z2   Z3 + Z 4   Z5 + Z6   18 + 38 
a1 =  1 *m =  *m= *m =  * 2.5 = 70mm
 2   2   2   2 

Where, a1 = the center distance between input shaft and intermediate shaft.

 Z + Z8   Z11 + Z12   Z 9 + Z10   20 + 53 

a2 =  7 *m =  *m = *m =  * 2.5 = 91.25mm
 2   2   2   2 

Where, a2 = the center distance between input shaft and intermediate shaft.

Step 10:- calculation of face width

Using PSG data book table 8.32

b
m = = 10  b = 10* m = 25 +10 + 7b + 20 + 7b +10 + 25 = 25mm
m
Therefore, face width = b = 25mm
Table 3.3 Calculation for standard spur gear
No. Item Symbol Formula Example
Pinion(1) Gear(2)
1 Module M 2.5mm
2 Pressure Angle  200
Set Value
3 Number of teeth Z 22 35
4 Center Distance CD ( Z1 + Z 2 )m / 2 70mm
5 Reference Diameter d Z *m 55mm 87.5mm
6 Addendum A 1.00*m 2.5mm 2.5mm
7 Tooth depth H 2.25*m 5.6mm 5.6mm
8 Tip Diameter da d + 2m 59.5mm 92mm
9 Root Diameter df d − 2.5m 50.5 83mm

3.3 Design of shafts

I, diameter of grinder output (spindle) shaft

Equivalent torque= Te =  * d o3 ……………… (8)
16
Where Te =Equivalent torque
 =Shear stress of the gear shaft material.

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 Design of nine speed gearbox for grinding machine
Fn * L F *L
Te = M 2 + T 2 M =bending moment = = t
4 4 cos 
 =pressure angle,  = 200
T =twisting moment
7.207 *103 Nmm
Ft = pc =
m
7207 Nmm
= 2882.8 N
2.5mm
Ft = 2882.8 N

Ft * L 2882.8* 440mm
M= =
4 cos  4 cos 200
M = 337459.285Nmm
T =twisting moment= T12 = 190.988*103 Nmm from calculation of modulus

Te = M 2 + T 2 = 337459.2852 + 1909882

= 387756.60 Nmm

Te = 387756.60 Nmm = * * d o3
16
 = 137.34 N / mm 2 for 15Ni 2Cr 1MO

387756.60 Nmm = *137.34 N / mm 2 * d o3
16
387756.60mm3
do3 = = 14379.143mm3
26.9666

do = 3 14379.143mm3

do = 24.32mm  25mm

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 Design of nine speed gearbox for grinding machine
Figure 3.6 : output shaft

II, diameter of input shaft

Input speed for shaft one is 548rpm
2 NT 2 *548T
P= = 2*103 =
60 60
120, 000
=T
2 *548
T = 34.85Nm = 34850Nmm

T= * * d s31
16

34850 Nmm = *137.34* d s31
16
3
d s31 = 3 1292.368mm3

d s1 = 10.89mm

Figure 3.7: input shaft

III, diameter of intermediate shaft

Input speed for intermediate shaft is 264rpm
2 NT 2 246T
P= = 2*103 =
60 60
120*103
T= = 72.343Nm = 72343Nmm
2 264

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 Design of nine speed gearbox for grinding machine

T= * * d s32
16

72343 Nmm = *137.34* d s32
16

72343
3
d s32 = 3
26.966
d s 2 = 13.89  14

Figure 3.8: Intermediate shaft

IV, length of shafts

Assumed parameters
Length of shaft extended on both sides = 25mm
Distance between two successive gears = 10mm
L = 25 +10 + 7b + 20 + 7b +10 + 25
= 90 + 14b = 90 + 14*2.5 = 440mm
L = 440mm

3.3 Design of key for shafts

A key is a piece of mild steel inserted between the shaft and hub to connect these together in order to prevent
relative motion between them. It is always inserted parallel to the axis of the shaft. Keys are used as temporary
fastenings and are subjected to considerable crushing and shearing stresses. A keyway is a slot or recess in a
shaft and hub of the pulley to accommodate a key.
Width and thickness of the key can be taken from the chart and the length of it should be calculated. In order to
calculate the length of the key, following equation should be taken in account.

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 Design of nine speed gearbox for grinding machine

T= * * d 3
16
d d
T =F* = l * w * *
2 2
d t d
T = F * = l * * c *
2 2 2

Where, T = torque of the material

l = key length
t = thickness of key,
 = shear stress of key material and
 c = crushing stress
d = standard diameter of shaft material

i, dimensions of key for output shaft

Diameter of output shaft = do= 25mm

(T ) = * * do3
16

T= *137.34 * 253
16
= 387756.60Nmm
Shaft diameter = 24.32mm  25mm
Standard diameter is 30mm for selection of key dimensions

Table 3.4 : Proportions of standard parallel keys

Shaft diameter of (mm) Key cross-section

up to and including Width(mm) Thickness(mm)
6 2 2
8 3 3
10 4 4
12 5 5
17 6 6

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 Design of nine speed gearbox for grinding machine
22 8 7
30 10 8
38 12 8
44 14 9
56 16 10
58 18 11
65 20 12
75 22 14

N
The shear stress of the key material is 150
mm 2
t d
T = L * * *
2 2
T = 387756.6 Nmm = l *10mm *150 N / mm 2 *15mm
387756.6 Nmm
L=
10*150 N *15
L = 17.23mm
Length of the key= 17.23mm ………………………………………………………………1
N
The crushing stress of the key material is 250
mm 2

t d
T = L * * c *
2 2
10mm
387756.6 N / mm 2 = l * * 250 N / mm 2 *15mm
2

387756.6 Nmm
l=
5 * 250 N *15
l = 20.68mm
Length of the key = 20.68mm ……………………………………………………….4
Therefore, the key for the output shaft hub is 21mm which is higher than the maximum value of the calculated
length for key.

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 Design of nine speed gearbox for grinding machine

Figure 3.9: key for output shaft

ii, dimensions of key for input shaft

Diameter of input shaft = ds1=10.89mm

T= * * d s13
16

= *137.34*10.893
16
= 34850 Nmm

Shaft diameter = 10.89mm  11mm

Standard diameter is 12mm for selection of key dimensions

12 5 5

Width of the key 5mm

Thickness of key 5mm

d
T = l * w * c *
2
34856 Nmm
L= = 7.744mm
5mm *6mm *150 N / mm 2
L = 7.744mm
N
The crushing stress of the key material is 250
mm 2
t d
T = l * * c *
2 2
34850 Nmm
=
5 6
( * ) * 250 N / mm 2
2 2

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 Design of nine speed gearbox for grinding machine
l = 18.58667mm
Therefore, the key length must be equal or more than 18.58667mm

Figure 3.10 key for input shaft

iii, dimensions of key for intermediate shaft

Diameter of input shaft = ds2= 13.89mm

T= * * d s13
16

= *137.34*13.893
16
= 72346 Nmm

Shaft diameter = 13.89mm  14mm

Standard diameter is 17mm for selection of key dimensions

17 6 6

Width of the key 6mm

Thickness of key 6mm

d
T = l * w * c *
2
72346 Nmm
L= = 9.45mm
6mm *6mm *150 N / mm 2
L = 9.45mm
N
The crushing stress of the key material is 250
mm 2

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 Design of nine speed gearbox for grinding machine
t d
T = l * * c *
2 2
72346 Nmm
=
6 6
( * ) * 250 N / mm 2
2 2
l = 11.348mm
Therefore, the key length must be equal or more than 11.348mm

Figure 3.11 key for intermediate shaft

Table 3.5: summary of keys dimensions

Key used for Diameter(mm) Dimensions(w*t*l)(mm3)

Output shaft 25 10*8*20.68

Input shaft 10.89 5*5*18.58667
Intermediate shaft 13.89 6*6*11.348

3.4 Design of bearings

Bearing is a device that is used to enable rotational or linear movement, while reducing friction and handling
stress. Resembling wheels, bearings literally enable devices to roll, which reduces the friction between the
surface of the bearing and the surface it's rolling over. Input shaft and the output shaft is held by ball bearings.
Each shaft is consisted of two ball bearings which are tightly fitted to the shaft and to the housing.
3.4.1 Ball bearing calculation
For input shaft
hrs perday * 60 * days per year * year * rpm
L10 =
1000000

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 Design of nine speed gearbox for grinding machine
For this application,
Hours/day=6
Days=250
Years=2
Rpm=548
L10 Value can be calculated and it is 98.64 million revolutions.

C = P * ( L10 )1/3

For input shaft P = 2882.8N

C = P * ( L10 )
1/ 3

= 2882.8 N 3 98.64
= 13,319.8
Calculated C value for bearing is 13,319.8 = 13.32KN
Table 3.6: Basic static and dynamic capacities of various types of radial ball bearings
Basic capacities in KN
Single row deep groove ball Single row angular contact ball
bearing bearing
Bearing No. Static ( C0 ) Dynamic (C ) Static (C0 ) Dynamic (C )

200 2.24 4 __ __
300 3.60 6.3 __ __
201 3 5.4 __ __
301 4.3 7.65 __ __
202 3.55 6.10 3.75 6.30
302 5.20 8.80 __ __
203 4.4 7.5 4.75 7.8
303 6.3 10.6 7.2 11.6
403 11 18 __ __
204 6.55 10 6.55 10.4
304 7.65 12.5 8.30 13.7
404 15.6 24 __ __

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 Design of nine speed gearbox for grinding machine
205 7.1 11 7.8 11.6
305 10.4 16.6 12.5 19.3
405 19 28 __ __
206 10 15.3 11.2 16
306 14.6 22 17 24.5
406 23.2 33.5 __ __
207 13.7 20 15.3 21.2
307 17.6 26 20.4 28.5
407 30.5 43 __ __
208 16 22.8 19 25
308 22 32 25.5 35.5
408 37.5 50 __ __
209 18.3 25.5 21.6 28
309 30 41.5 34 45.5
409 44 60 __ __
210 21.2 27.5 23.6 29
310 35.5 48 40.5 53
410 50 68 __ __

Bearing number selected for input shaft C= 13.32 KN is 304 single row contact ball bearing
3.4.2 Needle Roller Bearing for Output Shaft Gear Wheels
Since the Constant Mesh technology is used, the output shaft gear wheels must be able to rotate freely on
bearings. Type of bearing is needle roller bearings.
Resultant force due to gear wheel A is calculated as follows.
P * 60
Torque transmitted, T =
2 N
2882.8 N * 60
=
2 (264)
T = 104.27 Nmm

2T
Tangential force, F = Ft =
R

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 Design of nine speed gearbox for grinding machine
2 *104.27 Nm
=
0.37
= 563.62 N
Normal load (Resultant force),
Ft
F=
cos(20)
563.62
=
0.9396
= 599.85 N
6hr / day * 60 * 250day / year * 2 year * 264rpm
L10 =
1000000
L10 = 47.52 millon revolution

Calculate C value for bearing

C = P( L10 )1/3
= 2882.8 3 47.52
= 10, 441.750
Calculated C value for bearing = 10, 441.750 = 10.441KN
Bearing number selected for input shaft C= 10.441 KN is 303 single row deep groove ball bearing.

3.5 Gear housing

The width of housing is 138.95 whereas the length and height of housing are 440 and 264.126 respectively. The
thickness of sheet metal used to construct housing is 5mm.
Procedures followed to construct housing are mentioned below
1. Take the plate of sheet metal and bend it into the required shape for both the top and
bottom case sections of the gearbox.
2. Use CNC milling machine to create the bearing holders from blocks of steel.
3. Weld the bearing holders to the top and bottom portions of the case respectively.
4. Cut out gussets from sheet metal and weld them to the bearing holders and housing
for support.

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 Design of nine speed gearbox for grinding machine

4 Result and discussion

We have made an attempt to design a Nine Speed Gearbox for low power applications. In this process we have
designed Spur Gears, Shafts, and Bearings. We have designed the CAD model in SOLIDWORKS.

Table 4.1: result and discussion for all components

No. component Dimension
Diameter length width Thickness Discussion
(mm) (mm) (mm) (mm)

1 Output shaft 24.32 440 Shafts used to hold gears of

Input shaft 10.89 440 different tooth number besides,
Intermediate shaft 13.89 440 it transmits torque and different
level of speed.
2 Key for output shaft 20.68 10 8 The main objective of key is that
Key for Input shaft 18.58 5 5 it holds gear in position on shaft.
Key for Intermediate 11.348 6 6 Prevent unnecessary movement
shaft of gear on shaft

Result and discussion for gear wheel

Gear Z(teeth) d=m*z d(mm) Discussion
1 22 2.5*22=55 55 The purpose of gear is
2 35 2.5*35=87.5=88 88 transmitting power, torque
3 33 2.5*33=82.5=83 83 and changing the direction
4 44 2.5*44=110 110 of motion. Under result
5 18 2.5*18=45 45 there is different type of
6 38 2.5*38=95 95 gear tooth which mesh to
7 32 2.5*32=80 80 each other in order to
8 41 2.5*41=102.5=103 103 different type of speed
9 46 2.5*46=115 115 ratio and torque.
10 28 2.5*28=70 70
11 20 2.5*20=50 50
12 53 2.5*53=132.5=133 133

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 Design of nine speed gearbox for grinding machine

Conclusion
We concluded that as per the design criteria, we have designed the gearbox for grinding and the design made
by us is safe and satisfactory and can be proceeded with the production process. Also, the step wise solution of
the present work would be beneficial as per an aspect of time and reducing complexity for designing the
gearbox. The ray diagrams are used to make the design more feasible concerning the number of teeth used in
gearbox and transmission ratio. The analysis shows that the gearbox can carry maximum stresses and
deformation under the safety zone. Based on the results, spur gear with a higher module is preferred if a large
amount of power is required to transmit.

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 Design of nine speed gearbox for grinding machine
References

1. Khurmi, R.S. and Gupta J. A textbook of refrigeration and air conditioning. 2nd ed. 2010. 454 p.
2. Piyush NarkhedGhaya A. Design And Analysis Of 9 Speed Gearbox. Int J Sci Res Publ. 10(6):831.
3. Shashank Pandey NNS& DPKS. MODELING, DESIGN & ANALYSIS OF DIFFERENTIAL GEAR
BOX AND ITS HOUSING THROUGH FEM, SOLIDWORK & ANSYS BENCHWORK. Int J Eng Sci
Res Technol. 6(9):3.
4. Neeraj Patel TG, B.Tech. Methodology for Designing a Gearbox and its Analysis. Int J Eng Res Technol.
55(01):1.
5. Budynas, G.R. and Nisbett KJ. Shigleys Mechanical Engineering Design. 8th Editio. McGraw-Hill
Companies; 2008. 67–410 p.
6. Achchagam K. Design data book for engineers. 2nd ed. 337 p.
7. Video. Design of gearbox parts [Internet]. 2019. Available from:
https://www.youtube.com/watch?v=_0rq4J63yeg&t=21s
8. Khurmi, R.S. and Gupta J. A Textbook of Machine Design. 14th Editi. Eurasia Publishing House (P.V.T)
Ltd; 2005. 12–30 p.

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Appendix

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Figure ; drafting for all components

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