Design of Gearbox 2

Give FEEDBACK: dpbhaskar@rediffmail.
com
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D.P.Bhaskar, Sanjivani COE Kopargaon
Multi‐speed Gear Box of Machine Tool
1.

Lathe
2. Shaping
3. Milling
4. Drilling
Single input speed (Motor speed) = nem n1 ,n2 ,n3 ,n4
Multi‐Speeds on Spindle shaft (Spindle Speeds) n5 ,n6 ,n7 , nz
n1 = nmin
The extreme spindle speeds
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nZ = nmax 2
Why Multi‐Speeds ? Different :
• Feeds
• W/P Materials
n1 • W/P Dimensions [D]
• Cutting tool materials
n2
n3
1
n4 1
n5
n6
n7
nem
n8
N9= nz
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Speed Regulations

Stepped Regulations Stepples Regulations

Discrete speed steps Continuous speed steps
n1
n2
nem
n3
n4
n5
nz
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Progression Laws
Why Progressions *To find different speed steps
*Find relation of two speed steps
Types of Progression Laws

1. Arithmetic progression (AP)
2. Geometric Progression (GP)
3. Harmonic Progression (HP)

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Z=Total speed steps (speeds) on spindle.
(n1, n2, n3, n4,……………………….., nz‐1,nz..)

LAW

Difference between 2 successive speeds is constant = at
a = (n – n )= (n – n )= (n – n )= (n – n )
t 2 1 3 2 4 3 z z‐1

Ration of 2 successive Speeds= Ø=Speed Ratio
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nmax =Maximum spindle speed (rpm)= nz
nmin= Minimum spindle speed (rpm)= n1

n1 =nmin
n2 =n1 + at
n3 = n2 + at =n1 + 2at
n4 = n3 + at =n1 + 3at
nz = n(z‐1)
( ) + at =n1 + (z‐1)at

Dk = Diameters to be Machined at Specific cutting speed (v)
=Upper limit of Diameter
∆Dk = Diameters Range = (D2‐D1)
∆
= (D3‐D2) ………

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AP Arithmetic progression
Maximum spindle speed (rpm), nmax =445 rpm
Minimum spindle speed (rpm), nmin=35 rpm
Number of speed steps, Z=12
Cutting speed, v=20 m/min.

D.P.Bhaskar,
Sanjivani COE 9
24/01/2017 Kopargaon

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Remarks @ AP

At low spindle speeds the diameter range is wide hence needs to
add more speed steps between calculated values.

At high spindle speeds, the diameter range is very narrow and hence some of the
speed steps are redundant.

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GP Geometric progression
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Geometric Progression Ratio

Speed Ratio

Range Ratio

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Progression ratio/ Speed ratio
Geometric progression (also inaccurately known as a geometric
series) is a sequence of speeds such that the ratio of any two
successive speeds of the sequence is a constant called the Geometric
progression ratio (speed ratio) of the sequence.

Range ratio
It ratio of maximum and minimum speed

GP

Maximum spindle speed (rpm), nmax =445 rpm
Minimum spindle speed (rpm), nmin=35 rpm
Number of speed steps, Z=12
Cutting speed, v=20 m/min.

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Remarks @ AP
At low spindle speeds the diameter range is wide
hence needs to add more speed steps between
calculated values.
At high spindle speeds, the diameter range is very
narrow and hence some of the speed steps are
redundant.
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AP
or
GP?
Variation in GP gives Optimum
Diameters is wide Distribution Of Gear
in AP than GP Speeds compared to
AP
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AP – GP‐ HP Comparison

Z N
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Effect of GP ratio
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Definition of preferred number/speed series
In gearbox design a set of preferred step ratio or preferred
numbers is used to obtain the series of output speed of
gearbox. The preferred step ratio is mentioned as basic series
named as R5, R10,R20,R40 and R80. Each basic series has a
specific step ratio. R [Charles Renard]
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1 Sequence 5 Gearing Diagram
Structural Formula
2
Structural Diagram
3
Ray Diagram
4
Speed chart
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Structural Formula
The maximum number of speed that can be obtained from
two shafts is three. Hence its necessary to
use intermediate shafts between the input shaft and output
shaft. The structural formula helps to arrive the number of
stages and required gears to obtain the desired speeds.
Z =P1(x1)*P2(x2)*....Pu(xu)
Structural Formula
P : Speed steps/ Pairs in any stage
X : Characteristic in stage





RULE
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HL=Z=6
VL=N+1=3
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BEST
1) MAX Node addition=7.5
RULE
2) P of Stage one should be less
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BEST
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Z=9
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Z=12
BEST
For More than 2 stages 1st and last stage P should be less
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RULE
Optimum SF
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A ray diagram is a representation of structural
formula. It provides information such as speed in
Definition
each stage, the transmission ratio in each stage, The
total number of speeds and its values.
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Ray diagram for Z=4
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RULE
Ray Diagram
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Definition
Kinematic/Gearing Layout
A kinematic layout is a pictorial representation
Ray Diagram of a gearbox, describing the arrangement of
gears. It provides information like number of
stages, number of shafts used, number of gear
pairs and its arrangement.
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RULE
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Gearing Diagram
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Z=12

Gearing Diagram
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Number of Teeth and Speed deviation diagram
Question
Write best Structural formula, Draw Structural

Diagram, Ray Diagram, Speed Chart, Gearing
Diagram, No of teeth, Speed Deviation Diagram
Ray Diagram, Speed Chart Gearing Diagram
e
Spindle speeds
Sppeds n1 n2 n3 n4 n5 6

Calculated 100 158 252.8 395 632 995.4
Round off 100 160 250 400 630 1000
Stage 1 No. Of Teeth Calculation
Ray Diagram
No deviation in speeds in stage 1
ZA=20 ZA’=50 GA=2.5
ZB=27 ZB’=43 GB=1.59
C1=70
Ray Diagram Stage 2 No. Of Teeth Calculation
Deviation in speeds in stage 2
ZC=20 ZC’=80 GE=4
ZD=38 ZD’=61 GD=1.631
ZE=61 ZE’=39 GC=0.639
C2=100
GE=4 GE=4
GD=1.6 GD=1.631
GC=0.635 GC=0.639
′ 400
/GD=400/1.635=244.64

′
′ 630
/GD=630/1.635=385.32
′ 400
/GC=400/0.639=626

′ ′ 630
/GC=630/0.639=986
n(TH) n(PR)
100 100
Deviated 160 160
Speeds 250 244.64
400 385.32
630 626
100 986
Speed Deviation ∆n
nth 100 160 250 400 630 1000

nact 100 160 244.64 385.32 4 986
∆n 0 0 ‐2.144 ‐3.67 ‐0.639 ‐1.40
Limit for speed deviations
∆n < ± 10(ɸ‐1)٪
∆n < ± 10(1.58‐1)=5.8٪
Speed Deviation
Diagram
Difference between number of teeth on
successive gears in change gear box
SPPU Questions

•Input speed= 120 RPM
•Draw structure diagram
•Find Spindle speeds.
•Speed trapped for given position
•Speed ratio?
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SPPU Questions
SPPU Questions
SPPU Questions
SPPU Questions

Design of Gearbox 2

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Give FEEDBACK: dpbhaskar@rediffmail.

Write best Structural formula, Draw Structural

Sppeds n1 n2 n3 n4 n5 6

nth 100 160 250 400 630 1000

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