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					Course : ME 684- Manufacturing Consideration in Design Problem Definition : Design and Development of Gear Box
2HP, 1400 rpm
Fig. Shaft Orientation

Design
100

of Gear Box Elements
I/P Shaft Dia. = 12mm Bore dia. d = 12 mm Hub dia.= 2d = 24 mm PCD = 3d = 36mm OD = 4d = 48mm Length = 1.5 d = 18 mm Thk .= 0.5d = 6 mm No of bolts n= 4 no’s Bolt size is M6 x 1p

1. Input Shaft :

(S.F.= 2)

2HP, 350 rpm Fig. Shaft Orientation
Material Table

2. Flange Coupling : Flange :
Per. Shear stress Mpa.
125 (HT) 50 50 100 50 125 (HT) 110 110 110 110 100

Component . Name
Input Shaft Flange left Key Bolts and Nuts Flange right Output Shaft Input Gear Bevel Gear Spur Gear Out put Gear Int. Shaft

Material
En 24 Steel En 8 Steel En 8 Steel En 24 Steel En 8 Steel En 24 Steel C 45 Steel C 45 Steel C 45 Steel C 45 Steel En 24 Steel

Bolt Size :

STD- IS:4218 (part iii) 1976

Width w = 5 mm Depth h = 5 mm Length l = 18 mm

Key way Size:

IS:2292 and 2293 -1974

O/P Shaft Dia. = 20mm No. of Spline = 8
ME 08 M 143, IITM
1

Srinivasa Rao Nandam,

Design of Gears Train
Speed reduction r1 = 2 Gear Type = Bevel Gear Angle of shaft Intersection = 90 ° Pressure Angle = 20 ° Modulus = 2 mm Speed reduction r2 Gear Type Intersection Angle Pressure Angle Modulus = 2 = Spur Gear = zero ° = 20 ° = 1 mm

Lewis Eqn.

Bevel Gear Train Design data
slno Parameter Input Gear Bevel Gear slno

Spur Gear Train Design Data
Parameter Input Gear Bevel Gear

a b c d e f g h

No of teeth 20 Bore dia. Hub dia Pitch dia Outer dia Hub width Face width Length 12 mm 32 mm 40 mm 45 mm 18 mm 15 mm 32 mm

40 12 mm 40 mm 80 mm 82 mm 12 mm 15 mm 27 mm

a b c d e f g h

No of teeth 35 Bore dia. Hub dia Pitch dia Outer dia Hub width Face width Length 20 mm 25 mm 35 mm 37 mm 10 mm 10 mm 20 mm

70 20 mm 45 mm 70 mm 72 mm 10 mm 10 mm 20 mm
2

Srinivasa Rao Nandam, ME08 M 143, IIT M

Assembly Sequence

Srinivasa Rao Nandam, ME 08 M 143, IITM

3

Manufacture Route
Manufacturing Sequence of Input Shaft Ø 16 x 100
Forged Rod
Sl.No Component 1 Input Shaft 2 3 4 5 6 7 8 9 Flange left Keyway Bolts & Nuts Flange right Output Shaft Input Gear Bevel Gear Spur Gear Pinion Output Gear Int. Shaft Roller Bearing Roller Bearing Roller Bearing Thrust Bearing Casing Half Casing Half Bolts and Nuts Material Raw Size En 24 Steel Ø 16 x 100 En 8 Steel En 8 Steel En 24 En 8 Steel Forged - HT 6x6x20 M6x1px 25 Forged - HT Manufacturing Process Qty Forging, HT, Turning, Keyway Cutting 1 Forging, HT, Turning, Drilling, Boring, 1 Keyway Cutting Milling, Grinding 6 Standard (similar size & weight) 4

En 24 Steel Ø 24 x 80 C 45 Steel C 45 Steel C 45 Steel C 45 Steel Forged - HT Forged - HT Forged - HT Forged - HT

Forging, HT, Turning, Drilling, Boring, 1 Keyway Cutting Forging, HT, Turning, Spline Cutting 1 Forging, HT, Gear Hobbling, Keyway cutting Forging, HT, Gear Hobbling, Keyway cutting Forging, HT Gear Hobbling, Keyway cutting Forging, HT, Gear Hobbling, Keyway cutting Forging, HT, Turning, Keyway Cutting SKF -1601 SKF -1602 SKF -1603 SKF -4002 Machining, drilling Machining, drilling Standard 1 1 1 1 1 2 1 3 2 1 1 12
4

Ø 12.5 x 100
Semi finished component

10 11 12 13 14 15 16 17 18

En 24 Steel Ø 20 x 110 STD STD STD STD Upper Bottom En 8 Steel Bore12 mm Bore15 mm Bore20 mm Bore15 mm M.S. M.S. M8 x1p

Ø 12 x 75
Finished component

Srinivasa Rao Nandam, ME08 M 143, IITM

Quality Issues
Location for Assembly

Sl.No 1 2 3 4 5 6 7

Component

Material

Wt.(Kg) Qty Price (Rs) 1 1 6 4 1 1 1 1 1 1 1 15/13/1/40/13/60/96/240/32/160/50/400/200/600/400/2/2/96/-

Input Shaft En 24 Steel 0.075 Flange left En 8 Steel 0.132 Keyway En 8 Steel 0.005 Bolts & Nuts En 24 Steel Rs 10/Flange right En 8 Steel Output Shaft En 24 Steel Input Gear C 45 Steel Bevel Gear Spur Gear C 45 Steel C 45 Steel 0.132 0.30 0.32 0.800 0.106 0.57 0.25

Fillet for strength

8 9 10 11 12 13 14 15 16 17 18

Output Gear C 45 Steel Int. Shaft En 24 Steel Roller Bearing Roller Bearing Roller Bearing Thrust Bearing Casing Half Casing Half Bolts & Nuts SKF 1601 SKF 1602 SKF 1603 SKF 4002 Upper Bottom En 8 Steel

Auto Shaft Alignment

Rs. 200/- 2 Rs. 300/- 1 Rs. 400/- 3 Rs. 500/- 1 0.02 1 0.02 1 Rs. 12/- 12

Reference
• • • • • • Gear supplier http://www.qtcgears.com/RFQ/default.asp Coupling supplier http://www.euroflex.co.in/ Bolt and Nuts supplier http://www.unbrako.in/unbrako_standard.htm Bearing supplier http://www.skf.com/portal/skf/home/products Bevel gear design web link www. nptel.iitm.ac.in/courses/IIT M/~4.pdf R.S. Khurmi, Machine Design Text Book- 2005

Raw Material Cost = Rs. 2420/Forging Cost @500 per Kg = Rs. 1600/Turning Cost @200 per Hr = Rs. 1200/Key way cutting @300 per Hr = Rs. 900/Drilling & Boring @300 per Hr = Rs. 600/Gear Cutting @300 per Hr = Rs. 2400/Labor Cost = Rs. 800/Miscellaneous = Rs. 500/Total Cost = Rs. 10,420/-

Business Price =Rs. 12,000/5

Srinivasa Rao Nandam, ME08 M 143, IITM

Compact Size Low Wt.3 Kg


				
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