ME365 Machine Design Fall 2014

hhhhhhhhhhhhhhhhhhhhhhhhh
Project: Gearbox, Single-Reduction
hhhhhhhhhhhhhhhh
Design a complete single-reduction, spur gearbox. The gearbox will be used to connect a wind turbine to an electric
power generator. The wind turbine transmits 50 kW of power, at 3000 rpm, to the input shaft of the gear box. The
output of the gear box must drive an electric power generator at 4000 rpm. The center distance for the gear pair must
not exceed 150 mm.
Specify two gears, two shafts, four bearings, and a housing for the gearbox. Make detailed drawings for the two
shafts (i.e. component or manufacturing drawings) and an assembly drawing for the entire gear box.
Report Outline:
1. Introduction: design objective
2. Design: dimension calculations according to the requirement.
!Gear design: using the given information, select material and based on stress and strength
equations calculate all parameters and dimensions for gears.
!Shaft design: analyze the load distribution and use stress-strength relation equations to calculate
shaft dimensions.
!Bearing design: select bearings according to the load, life and reliability.
!Keys design: determine the shear and crushing stresses that are being developed on the keys, and
select material and size of the keys accordingly.
!Case design: use your materials and general knowledge to determine the case dimensions, and
make sure it is durable and compact. There are no formal design calculations required for the case.
3. Assembly and individual part drawings.
4. Conclusion: What did you learn in this project?
Recommendation:
Use the power transmission case study presented in Chapter 18 (page 933) of your book as a guiding
example on how to design the gearbox.
Additional design requirements:
Fatigue loads:
- for bearings:
Minimum design life for bearings is 6 years.
- for gears:
Use 107 cycle 99% reliability data at full load conditions above.
- for shafts, keys, other parts:
Use infinite life for the full load output case, because of the high number of load cycles.
Reliability and minimum factors of safety:
Design shafts to 90% reliability for fatigue. Minimum nf = 2.0, ny = 2.0.
Select bearings for 99% reliability (n = 1.0 is ok here because of high reliability)
Check bearings for static C0 failure using full load conditions, n = 1.5 minimum.
Design gears for 99% reliability, 107 cycles, fatigue safety factors are 1.2 surface, 1.5 bending.
Any other parts included in your design should have yield and fatigue factors of safety of at least 2.0 with
90% reliability.
Weak link design:
Design the input shaft key to fail by crushing before any of the other parts of the gearbox yield. (Failure is to occur in
this weakest key first, protecting the rest of the gear-box from accidental overloads). This will make this key the
weakest link in the system. Calculate the yield and fatigue factors of safety for this input key design.

Grading sheet
Gears design: Equivalent design loads. Diametral pitch. Number of teeth.
Tooth Quality (Qv). Bending and wear factors of safety are minimized. Gear
face width. Discuss material selection. Shaft center-distance constraints met.
Heat treatment. Attachment to shaft(s). Include a summary of the results at the
end of the section.
Shaft design: All shafts meet stress criteria. Factors of safety (static and
fatigue). Stress concentrations. Shaft material selection discussed. Heat
treatment. Shafts fit the bearings. Shafts constrained axially. Part drawings as
needed (sizes, fillets, shoulders, key slots, etc.). Include a summary of the
results at the end of the section.
Bearing design: Bearing forces correctly resolved. Bearing sizes are consistent
with other calculations. Correct procedure used to find Fd and C10. Include a
summary of the results at the end of the section.
Keys (or other locking devices): Correct calculation method used for shear and
crushing. Slot size and depth reasonable. Factors of safety are above 2.0. Does
input key protect gearbox from overloads while adequately transmitting normal
service loads? Include a summary of the results at the end of the section.
Housing: Housing is designed so that all components can fit in, be easily
assembled and disassembled, and allow for oil to be held inside the casing for
gear lubrication purposes.
Bonus points: Sound engineering effort made to reduce overall weight.
Innovative design (clear and reasonable). Well done drawings (see Figure 18.3,
page 950 for what represents a well done drawing for the shafts and the ME180
notes for what represents a well done drawing for the housing and assembly).

Up to 5pts in all

5 pts

15 pts

25 pts

25 pts

30 pts

Penalties:
Make sure to schedule your work on the project such that you meet the due dates for project deliverables.
Individual member calculations have to be submitted in addition to the team submission; failure to do so will
result in a grade of zero, on that assignment, for the student who didnt submit his/her work. No late
submissions are allowed for a team member once the team has submitted the assignment.
Failure to submit scheduled deliverables by the due date, as a team, will result in 10% grade penalty, per day,
on that deliverable. This clause doesnt supersede the previous one.

Additional project requirements:

Develop a computer code in MS Excel, Matlab or MathCAD to assist you in the design process. Please note
that the design process is iterative in nature and attempting it without the use of computers is not feasible.
Every student has to keep a logbook on the design activities performed toward the project. The logbook of
each project team member has to be turned in with the project.
Each team member has to perform the project calculations independently and discuss their results with the
team members. After reviewing each members results on a given assignment, the team will prepare the
required materials for that assignment and submit one solution on behalf of the team. Individual member
calculations have to be submitted also with the team submission.

Turn in the following information at the beginning of the lecture on Nov 12, 2014.
(Only one sheet needed per team.)
We agree to work as a team on the gear box project for ME 365 Fall 2014.
We agree that we will all receive the same grade for this project, before the application of the peer evaluation factor.

Name of Student #1 ____________________________________________________

Signature of Student #1 _______________________________ Date: _____________

Name of Student #2 ____________________________________________________

Signature of Student #2 _______________________________ Date: _____________