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Gear Ratio and Gearbox Calculations

The document discusses the calculation and design of gears for a gearbox. It includes calculations for gear ratios, tangential tooth loads, velocity factors, power transmission, and specifications for each gear. The key steps are: 1) Calculate gear ratios, resistance forces, and velocity to determine the required gear ratio of 9.35667 for power transmission. 2) Calculate minimum tooth numbers and design gear box with initial gear ratios of 3.1 and 3.13. 3) Specify materials, dimensions, and parameters for 4 gears to safely transmit the maximum power of 7.4-7.6kw within design limits.

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Harshit Mishra
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568 views6 pages

Gear Ratio and Gearbox Calculations

The document discusses the calculation and design of gears for a gearbox. It includes calculations for gear ratios, tangential tooth loads, velocity factors, power transmission, and specifications for each gear. The key steps are: 1) Calculate gear ratios, resistance forces, and velocity to determine the required gear ratio of 9.35667 for power transmission. 2) Calculate minimum tooth numbers and design gear box with initial gear ratios of 3.1 and 3.13. 3) Specify materials, dimensions, and parameters for 4 gears to safely transmit the maximum power of 7.4-7.6kw within design limits.

Uploaded by

Harshit Mishra
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

GEAR CALCULATION

Various notations:-
FR= Rolling resistance

FG= Gradient resistance

V= Velocity

FA= Air drag

TP=Traction effort

Calculation:-
Step 1:- Gear ratio

FR= 4m=0.1*252*9.81 =247.212 N

FG= 252*9.81*Sin35.= 1417.949 N

V= 3.14*d*N/60 x = 3.14*0.55342*2600/60 x

FA= 0.24(110.119/x)2= 2910.286/x2

TP=19.68* 0.8x/0.5342 =53.89x Nm

Then,

53.899 x3=1665.16x2 -1637.039

X=29.57

CVT gear ratio= 3:1 (max), 0.45:1 (min)

Finally achieved gear ratio through Gear box=9.35667

STEP 2:- Calculation for gear box

Minimum number of teeth:-

Gear ratio of 1&2= 3.1


Gear ratio of 3&4= 3.13

By using the formula of Tmin

Tmin=2*1/ξ([Link] 1+XG(XG+2) sin2ɸ-1)

Tmin=15.1348 ɸ= (20.) Pressure angle

STEP 3:- Designing of gear box


Material for gears:-

Name= 8620 stee l

Sut=800 MPa, Sut= ultimate tensile stress

Syt=600 MPa Syt= ultimate yield stress

HBN=300

Elongation= 17%

Poison’s ratio= 0.25

Bulk modulus =110 GPa

For gear 1:-

At high gear ratio:- 3:1 (hill climb)

Then

Restricting rpm of engine = 2700 rpm

Then,

np1 =2700/3=900 rpm

v= πdN/60= π*m*20*900/60=2356.196 m/s


WT=Tangential tooth load

WT=σ*CV*b*pc*Y

Where,

Cv=velocity factor

b= face width

pc=

y= Lewis form factor

y=0.154-0.912/20= 0.1084

CV= 6/6+2.356= 0.718

B=25

Pc=7.3531

Now ,

WT=266.67*0.718*25*7.354*0.1084

WT=4075.29

Power= 9.6 kw

Note:- Above value of power is larger than maximum power we are going to
transmit which is 7.4kw . Hence the design is safe

For gear 3:-

i n3= 2700/3*3.15=289.389 rpm

v= πdn/60= π*m*23*289.389/60= 1.0450 m/s

y= 0.154-0.912/23=0.114

CV= 6/6+0.114= 0.851

B=30
Pc=9.424

Now,

WT= σ*cv*b*pc*y

WT= 266.67*0.851*30*9.424*0.114

WT= 7314.17

Power=7.6 kw

Note:- Above value of power is larger than maximum power we are going to
transmit which is 7.6kw . Hence the design is safe.

GEAR SPECIFICATIONS
VARIOUS NOTATIONS:-
m= module

pitch circle idea (pcd)=mT

TN= number of teeth on gear n

For gear 1:-


m= 2.5mm

T1=20

Pcd= 50mm

Addendum circle dia= 50+2*2.5= 55mm

Deddendum circle dia= 50-2(1.25*m)= 43.76 mm

Min. tooth depth= 2.25 m=5.625mm

Tooth thickness = 3.925 mm


For gear 2:-
m= 2.5mm

T1=20*3.15=63

Pcd=157.5mm

Addendum circle dia= 157+2*2.5= 162.5mm

Deddendum circle dia= 157-2(1.25*2.5)=151.25 mm

Min. tooth depth= 2.25 m=5.625mm

Tooth thickness = 3.926 mm

For gear 3:-


m= 3mm

T1=23

Pcd=69mm

Addendum circle dia= 69+6= 75mm

Deddendum circle dia= 69-2(1.25*3)=61.55 mm

Min. tooth depth= 2.25 m=6.75mm

Tooth thickness = 4.71 mm

For gear 3:-


m= 3mm

T1=72

Pcd=216mm

Addendum circle dia= 216+6= 222mm

Deddendum circle dia= 216-2(1.25*3)=208.5 mm


Min. tooth depth= 2.25 m=6.75mm

Tooth thickness = 4.71 mm

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