Importance of Gear Box

What is Gearbox? A Gear Box is actually a speed variable device which changes the speed of
power transmission device according to the requirements of torque. We normally use various
power transmission devices like lathe machine, drilling machine, milling machine or any other
machine tools which require power at different torque or speed as per the will of operator or
based on the operation performed. High torque operations require low speed and vice verse. E.g.
when we drive vehicle at steeper road, we lower the speed to have increased torque. Power and
torque are directly proportional but speed and torque are inversely proportional according to
formula:

Power transmitted = 2 x PI(=3.14159) x Speed x Torque/60.0 Watt

Hence, to perform different operations that require different torque or power and thus, we can
fulfil the requirements by changing the speed. This speed variation can be done by using
different gear having different teeth cut on it on various shafts at proper distance to have perfect
mesh in between the two gears. In case of lathes, milling machines the speeds are fixed by the
required cutting feed and/or cutting speed for a range of materials. Low strength materials can be
cut at higher speed and high strength material required higher torques so that speed needed is
very low compared to that of low strength materials. Also in case of auto-mobiles maximum and
minimum speeds of the vehicle determines the size of gearbox.
Design procedure for Gear Box
Follow this procedure to have idea about how to design a complete Gear Box with each
component's individual design. Determine the maximum and minimum speeds of the output
shaft. Calculate the number of steps or speed reduction stages for this range. This depends on the
application as well as space optimization. Higher reduction stages require more space because of
more number of gears and shafts requirements.

1. Select the type of speed reducer or gear box based on the power transmission
requirements, gear ratio, positions of axis, space available for speed reducer. Also make
sure that for low gear ratio requires single speed reduction. Select worm gears for silent
operation and bevel gears for intersecting axis.

2. Determine the progression ratio which is ratio maximum speed and minimum speed of
output shaft of Gear Box. The nearest progression ratio should be a standard one and is
taken either from R 20 or R 40 series.

3. Draw the structural diagram and kinematic arrangement indicating various arrangement
possibilities during speed reduction or increment.

4. Select materials for gears so that gear should sustain the operating conditions and
operating load. Normally cast iron is chosen for housing and cast steel or other alloy can
be selected as per the load requirements.

5. Note down the maximum power out put in Horse Power (H.P) or transmission power and
revolution per minute of shart i.e. rpm of each shaft.

6. Determine the centre distance between the driven and driver shaft based on the surface
compressive stress.

7. Determine the module of gear by beam strength as well as fix the number of teeth
required.

8. Calculate the diameter of the shafts by torque requirements and bending moment
considerations.

9. Calculate the key size, shape or type of transmission keys for each gears.

10. Select appropriate fit and tolerance for mating parts like shaft and gear.

11. Select bearings types based on the loading and operating conditions. Also make sure to
include consideration of maximum speed and expected life of gears and gear box.
Normally ball bearings and roller bearings are used for small size of gearbox because
they have lower thrust requirement due to low speed reduction.

12. Make the shaft stepped or provide collar to prevent axial displacement of bearing and
gear.
13. Provide suitable clearance between gears and walls of the housing of gear box and based
on this considerations design the casing/housing of gearbox.

14. Complete the design of casing. One should Provides fins if necessary to have increased
heat transfer by convection and conduction. Put inspection hole/man hole as well as drain
hole to drain lubricating oil. Also provide oil level indicator to have proper amount of oil
during operation, if not put, this will lead to failure of gear and shaft due to over heating
or due to frictional failure. Provide transportation hooks for transporting the gearbox
from one place to another or during installation and maintenance. Also design gear
changing lever accordingly.

15. Draw neat and clean working drawings in suitable software like AutoCAD, Pro Engineer
etc., indicating required details during manufacturing or assembly.