Computer Aided Design of Multi-Stage Gearboxes
Computer Aided Design of Multi-Stage Gearboxes
Abstract - Gearboxes are the most important and complicated programs are used for designing gears and gear boxes such as
part of machine tools, there are a great lack of an integrated KISSsoft [11], Program 580 [12], MD design [13] and Amtec
manual and/or computerized design of gearbox, this problem software [14]. KISSsoft is a program for sizing, optimizing
motivate to made a solution. The developed software called and recalculating designs for machine components such as
(GearBox LAB) for design and simulate multi-stage gearboxes, it
gears, shafts and bearings, screws, springs, joining elements
is created by using Visual Basic6 (VB6) programming language.
The software considers optimum structural diagram, speeds and belts. Program 580 is used to design a gearbox for the
design (theoretical, actual and their errors), speed chart, minimum weight. It is also useful in estimating the cost of a
kinematic diagram, design of gears, shafts, keys and spline, gearbox before it is manufactured. MD design software is used
bearing selection, shafts axis layout, gear box dimensions, fixing to generate a gear model and subsequent recalculation of the
bolts and foundation studs, gear meshing and bearing frequencies kinematics and single stage spur gears described how to check
as well as the Campbell diagram. The program is helpful for this construction. Amtec software is used to determine the
mechanical designers, researchers, students, troubleshooters as gears dimensions for single stage, it is very useful for checking
well as quality control and vibration engineers.
tooth profile, reasoning, noise reduction, bearing load and
flash temperature. The design and calculations software for
Index Terms — Computer aided design, design techniques,
simulation, software design, machine tools.
multi stages gear boxes are limited to only one step or output
rotating speed, [20].
From the literature review it is clear that there is a great lack in
1. INTRODUCTION the specific design applications such as machine tool gear
Machine tools use a gear box driven by electric motors boxes, like those concerned with machine elements [15, 16]. In
allowing the operator to select suitable cutting speeds and this paper the design of machine tool gear boxes is
feeds entirely through the gearboxes. Gearboxes also allow the computerized using visual basic 6 (VB-6) [17] considering the
input shaft and the output shaft to be in different directions. selection of electric motor, stepped diagram, finding the gear
Gearboxes save money, time and power consumption in metal module, gear ratios, calculates the number of teeth of
cutting. References [1-6] concern the design of machine tool individual and cluster gears, limitations in the choice of the
gear boxes, while [7-9] concern the design of machine number of teeth in the gear trains, used in the gear boxes, and
elements. Computer-aided design (CAD) is the use of computing torque regulation of speed, Laws of stepped
computer systems to assist in the creation, modification, regulation, progression, No. of speed steps, break up of speed
analysis, or optimization of a design [10]. CAD software is steps, structural formulae, structural diagram, selection of best
used to increase the productivity of the designer, improve the structural diagram, speed chart, kinematic and shaft sizes, as
quality of design, improve communications through well as gearbox gears and bearings noise and vibration
documentation, and to create a database for manufacturing. frequencies as well as Campbell diagram is achieved.
CAD is the technology concerned with the use of digital Campbell diagram is a mathematically constructed diagram
computers to perform certain functions in design. This used to check for coincidence of vibration sources with natural
technology is moving in the direction of greater integration of resonances.
design and manufacturing activities. These activities have The gear box size is estimated and can be minimized. Design
traditionally been treated as distinct and separate functions in a case study of speed gear box for lathe machine is solved
production firm. Ultimately, CAD will provide the technology manually and by using the written program. Good agreement
base for the computer-integrated factories of the future. Some between both methods is achieved. The program is essential
for professional mechanical designers, researchers, students,
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troubleshooters as well as quality control and vibration
engineers. It enables them in analyzing, simulation, redesign of
multi stage gear boxes. Moreover, it helps them in both design,
2. Theoretical Design Procedure:
production and operation stages.
In this section, it indicate to all calculation processes that
1.2 HELPFUL HINTS software consider in programming.
2.1 Gearbox speeds regulations:
In machine tools, stepped speed regulation obtained by
more than one way using different progression as geometric,
harmonic, logarithmic and differential progression.
Differential progression is the best one to achieve speed
proximity. However geometric progression is widely used in
machine tools as an international standard. Speeds in
geometric progression are estimated as the following form:
First Speed
Second Speed
Third speed
Generally
Subscripts:
I II I II
n1 n1
n2 n2
n3 n3
Figure (1) Speed Chart, Flow diagram & Kinematic diagram of 3 Speeds
Gear Box.
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Flow Diagram and Speed Chart are very similar to each
other except speed charts are constrained with reduction ratio
values however flow diagrams doesn't have any abidance to
numbers, it only gives a general distribution of speed. Shaft
are expressed as (I, II, III, …. ) and also speeds as horizontal
lines (n1, n2, n3, ……. ) as shown in figure (1):
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Box Casing wall thickness can be determined as a function of
material and hardened condition 3. THE SOFTWARE:
The software is produces to design multi-stage gearboxes
with (2, 4,6,8,9,12,16,18 & 24) speed. The design include
gears design, speeds regulation, shafts design, keys design, and
kinematic diagram also bearing and gear meshing frequencies
are determined, gear box casing and top cover dimensions.
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A
Start
Input Speed 1
Input Gear Data (B)
Gearbox Speeds
Check data
Completion
Shaft Design
Figure (4-a) Gear Box Design Flow Diagram Figure (4-b) Data Input Sequence
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3.3 Software (GUI) windows:
In this part, it discuss the (GUI) windows that users can
deal.
3.3.1 Welcome Screen:
The screen Shot of the welcome screen is shown in
Figure (5). It shows the name of software (GEARBOX Lab),
author and supervisors. This part of GEARBOX Lab is
concerned with multi-stage gear boxes (MSGB) design.
Figure (7) Screen shot of gears number of teeth, modules & dimensions.
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3.3.9 Frequencies of Gearbox Components Window:
Figure (13) gives a kinematic diagram of gear box,
bearings frequencies and gear meshing frequencies for
selected speed, the user can select the required speed and
kinematic diagram using speed scroll bar.
Figure (11) Screen shot of gear box shafts design. Campbell diagram is used to illustrate interferences
between natural frequencies and common exciting forces.
3.3.8 Gearbox Casing Dimensions Window: Excitation can be stationary, rotating, static, dynamic and
It gives designed dimension of gears with neat sketch synchronous. Campbell Diagrams investigates the dynamic
according to previous designed data. behavior of the system, For gear box, eigenfrequencies are a
function of shafts speed, critical speeds are the intersection
points of natural frequency curves with 1x n line, natural
frequencies depend on shaft speed, critical speeds do not. In
the case of a gear box, gear meshing frequency is plotted
against spindle running speed. Three windows are given to
check for coincidence of vibration sources with natural
resonances. Figure (15) presents the screen shot of Campbell
diagram for each gear mesh and its harmonic frequencies at
different speeds. It gives a plot of Campbell Diagram between
rotating speed and gear meshing Frequencies for each gear
group and its harmonic frequencies at each speed. The window
contains four parts namely; arbitrary input data (Speed
Figure (12) Screen shot of gear box casing dimensions.
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number, Reduction Ration Number), Speed cursor of the system. For this reason the use of proximity diagram is
corresponding to probable frequencies, frequency cursor essential. Figure (17) gives the software menu of Campbell
corresponding to probable rotating speeds, digital values of diagram considering its two proximity ratios at each speed.
rpm according to excited frequency. Beside the chart there are four major parts in the window
namely; arbitrary input data (Speed step number, Reduction
Ration Number, Proximity Ratio), speed cursor corresponding
3
to probable frequencies, frequency cursor corresponding to
probable rotating speeds, digital values of rpm according to
excited frequency.
2
1
3
1
4
Figure (15) Screen shot of Campbell diagram for each gear
mesh and its harmonic frequencies at different speeds.
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Gears Pitch Gears Dedendum
Gears Width (cm) Gear Meshing Frequency Manual Solution CAD Solution
Diameter (cm) Diameter (cm)
Manual CAD Manual CAD Manual CAD 1 355.7 355.7
z1 6.6 6.6 6.23 6.23 1.2 1.2 Gear Group 2 323.4 323.4
z2 1.2 1.2 3 362.2 362.2
8.4 8.4 8.03 8.03 4 497.1 497.1
z3 5.85 5.85 5.48 5.48 1.2 1.2
Table (5) Gear Meshing Frequency (Hz) in both Manual
z4 9.15 9.15 8.78 8.78 1.2 1.2
& CAD Solutions at 770 rpm.
z5 1.2 1.2
7.5 7.5 7.13 7.13 Bearings Frequencies Manual Solution (MSGB)
z6 7.5 7.5 7.13 7.13 1.2 1.2 Solution
z7 5.85 5.85 5.48 5.48 1.2 1.2
FTF1 3.2 3.2
z8 9.15 9.15 8.78 8.78 1.2 1.2
BPFI1 39.2 39.2
z9 11.2 11.2 10.70 10.70 1.75 1.75
BPFO1 25.4 25.4
z10 8.8 8.8 8.30 8.30 1.75 1.75 Shaft No. 1
z11 1.75 1.75
BSF1 30.2 30.2
6.6 6.6 6.10 6.10
z12 1.75 1.75 FTF2 3.2 3.2
13.4 13.4 12.90 12.90
z13 3.2 3.2 BPFI2 39.2 39.2
24.4 24.4 23.40 23.40
z14 3.2 3.2 BPFO2 25.4 25.4
15.6 15.6 14.60 14.60
z15 3.2 3.2 BSF2 30.2 30.2
8 8 7.00 7.00
z16 32 32 31.00 31.00 3.2 3.2 FTF1 2.5 2.5
Table (2-b) Gears Pitch Diameter (cm), Gears Dedendum BPFI1 31.1 31.1
Diameter (cm) & Gears Width (cm). BPFO1 20.2 20.2
Shaft No. 2
BSF1 24 24
Theoretical Speeds Actual Speeds FTF2 2.5 2.5
Speeds Errors (%)
(rpm) (rpm) BPFI2 31.1 31.1
Manual CAD Manual CAD Manual CAD BPFO2 20.2 20.2
nth1 770 770 758.75 758.75 1.46 1.46 BSF2 24 24
nth2 616 616 617.4 617.4 -0.23 -0.23 FTF1 2.5 2.5
nth3 485.1 485.1 485.1 485.1 0.02 0.02 BPFI1 31.1 31.1
nth4 385 385 394.73 394.73 -2.53 -2.53 BPFO1 20.2 20.2
nth5
Shaft No. 3
308 308 293.63 293.63 4.67 4.67 BSF1 24 24
nth6 242.55 242.55 238.93 238.93 1.49 1.49 FTF2 2.5 2.5
nth7 192.5 192.5 187.73 187.73 2.48 2.48 BPFI2 31.1 31.1
nth8 154 154 152.76 152.76 0.81 0.81 BPFO2 20.2 20.2
nth9 123.2 123.2 121.28 121.28 1.56 1.56 BSF2 24 24
nth10 96.25 96.25 98.68 98.68 -2.52 -2.52 FTF1 3.3 3.3
nth11 77 77 77.54 77.54 -0.7 -0.7 BPFI1 47.6 47.6
nth12 61.6 61.6 63.09 63.09 -2.42 -2.42 BPFO1 33.2 33.2
Shaft No. 4
nth13 48.5 48.5 46.93 46.93 3.26 3.26 BSF1 32 32
nth14 38.5 38.5 38.19 38.19 0.81 0.81 FTF2 3.3 3.3
nth15 30.8 30.8 30.01 30.01 2.56 2.56 BPFI2 47.6 47.6
nth16 24.26 24.26 24.42 24.42 -0.68 -0.68 BPFO2 33.2 33.2
Table (3) Theoretical Speeds (rpm), Actual Speeds (rpm) BSF2 32 32
& Speeds Errors (%). FTF1 5.5 5.5
BPFI1 88.5 88.5
Gearbox Dimensions Manual Solution CAD Solution BPFO1 65.5 65.5
k1 0.87 0.87 Shaft No. 5
BSF1 45 45
k2 0.79 0.79
kc 0.7 0.7 FTF2 5.5 5.5
kf 1.74 1.74 BPFI2 88.5 88.5
dcb 1.3 1.3 BPFO2 65.5 65.5
bs 7.8 7.8
BSF2 45 45
dfb 2.7 2.7
kff 4.1 4.1 Table (6) Bearings Frequencies (Hz) in both Manual &
Wf 6.8 6.8 CAD Solutions at 770 rpm.
Table (4) Gearbox Dimensions (cm) in both Manual & CAD
Solutions.
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Potential Benefits That Result from Implementing CAD. [13] Tutorial_gearbox_2012_en," Tutorial for gear design and calculation
with MDESIGN gearbox", Available from
Improved mechanical engineering designers productivity and
http://www.driveconcepts.com/info/tutorial_gearbox_2012_en.pdf
Minimize manual process errors in designs, Shorter design [14] Sigma-sh(Eng), "[1] involuteΣ(Spur and Helical Gear Design)",
times, Reduced engineering personnel requirements, Customer Available from http://www.amtecinc.co.jp/sigma-sh(Eng).pdf
modifications are easier to make, Faster response to requests [15] Adeyeri Michael Kanisuru, Adeyemi Michael Bolaji, Ajayi Olumuyiwa
for quotations, Improved accuracy of designs, Provides better Bamidele & Abadariki Samson Olaniran, “Computer Aided Design of
Couplings”, International Journal of Engineering (IJE), Volume (5) :
functional analysis to reduce prototype testing, Assistance in Issue (5) : 2011
preparation of design documentation, Designs have more [16] A.P. Azodo, B.Eng, S.B. Adejuyigbe, Ph.D. M.A. Waheed, Ph.D. and
standardization, Better designs provided, Improved O.U. Dairo, Ph.D. “Computer Aided Design of Mechanical Clutch.”,
productivity in machine tool design, Helps ensure designs are The Pacific Journal of Science and Technology , Volume 13. Number 2.
November 2012 (Fall).
appropriate to existing manufacturing techniques, Saves [17] Richard J. Simon, Richard Peasley, "Using Visual Basic 6.0", 1998.
materials and machining time by optimization algorithms, [18] Calculation of the gear and bearing frequencies, 2007, www.kisssoft.ag
Provides operational results on the status of work in progress, [19] Gearbox Design Lecture 17, Available from
Makes the management of design personnel on projects more http://nptel.iitm.ac.in/courses.
[20] MDESIGN gearbox 2010, design and calculation software for
effective, Assistance in inspection of complicated designs, multi stage gearboxes. Drive Concepts GmbH, 2010
Better communication interfaces and greater understanding
among engineers, designers, drafters, management, and
different project groups.
5. CONCLUSION:
1. A reliable, user friendly, integrated, accurate, faster
software and in a good agreement with the manual
design of machine tools gear boxes is achieved.
2. The given software is an integrated tool that bridges the
gap exist in the design of machine tools multi stage gear
boxes.
3. The program helps in the design, modification and
analysis of machine tool gear boxes.
4. The program is fruitful for professional mechanical
designers, researchers, students, troubleshooters as well
as quality control and vibration engineers in several
engineering fields such as machine tools, vehicles and
mechanical power transmission.
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[5] Nasser A., "Machine Tool Design (Power Transmission)", Faculty of
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[6] SEN G.C., Bhattacharyya A., "Principles of Machine Tools", Second
Edition, 2009.
[7] Andrew D. Dimarogonas, "Machine Design: A CAD Approach", Second
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