Running head: GEAR DESIGN PROJECT 1

Gear Design Project

Students Name

University
 GEAR DESIGN PROJECT 2

Name:

Cover Sheet

Motor Gearhead Design; MIE 413, Mini-Project 1, Spring 2021

Certification: I certify that the work I am submitting is my work alone, that I have not

collaborated or consulted with, nor have I provided any information to any individual on any

aspect relating to this project.

Printed name………………………………………….

Signature ……………………………………..

Listing of Gears Used

This cover page must be the first page of your submission. List all gears in which they transmit

power from the motor shaft to the gear output. Number the gears sequentially from 1 in the table

below and make corresponding annotations in the drawing. For each load, also list the pitch,

number of teeth, pitch diameter and face width and indicate whether the equipment is a pinion

(P), Gear (G), or idler (I).

Gear Gear Pitch, P Numbe Pitch Face Pinion,  

Parameter Numbe r of Diameter Width Gear or

r Teeth Idler, P, G

or I
Units teeth/inch inches inches  

diameter
 GEAR DESIGN PROJECT 3

Entry Note From List Integer Decimal Decimal Upper Case  

Number Number
Example   12 27 2.25 0.875 P  

  1  80 24 2.12 0.768 p  

  2  100 26 2.21 0.843 G  

  3  64 27 2.14 0.873 P  

  4  48 35 3.12 0.967 I  

  5  32 40 3.24 0.981 P  

  6  6 37 3.1 0.923 G  

  7  24 31 3.04 0.916 G  

  8  16 25 1.78 0.807 I  

  9  12 36 3.54 0.987 P  

  10  10 24 2.12 0.768 p  

  11  8 26 2.21 0.843 G  

  12  6 27 2.14 0.873 P  

  13  20 35 3.12 0.967 I  

  14  100 40 3.24 0.981 P  

  15  80 37 3.1 0.923 G  

  16  16 31 3.04 0.916 G  

  17  12 25 1.78 0.807 I  

  18  64 36 3.54 0.987 P  

  20  6 26 2.21 0.843 G  

Gear Design Project

Scaled dimensioned layout of the gear system showing principal dimension drawing and

sketch

Gears are a group of toothed members transmitting rotary motion from one shaft to the

next. A good example such are spur gears whose main purpose is transferring speed between

parallel shafts (Kissling, Stolz & Türich, 2019). According to Kissling, Stolz & Türic, (2019),

these gears have teeth that are parallel to the shaft axes. Our study will focus more on the pitch

and diameter, scaled dimension, sketch, layout drawings, face width, idlers, pinion, gear and

number of teeth. Kissling, Stolz & Türich, (2019) argues that another portion of the research will

dwell on nomenclature and geometry. Keerthi, Sandya & Sriniva, (2016) argue that the main

purpose of these dimensions is to provide ratios of angular velocities, which are always constant.

Tong (2016) believes that it should not fall below two or above when they come into and out of

mesh. This acceptable profile only fits gears with between 20 to 40 teeth. We can use the angular

velocity, d as the pitch diameter, r as the circle radius for the pitch and subscripts p and g pinions

and gear, respectively. We get an equation as W p /Wg = - dg/ dP =

The face width is C = (dg +d p)/ 2 = rP +rg

Stage Sizing

In this research, we design a gearhead for an industrial motion controller for precision

positioning. This study has sponsorship from a Maxon A-max 22 DC motor. Its design fits
 GEAR DESIGN PROJECT 5

perfectly within the diameter of a machine housing 22 mm ±1, which made it have a sleek

appearance, leading to the controller's smooth working. The gearhead had a reduction ratio of

12:1 (Tong, 2016). Under a uniform load condition, the motion controller operation was at 99%

reliability, working for 1000hrs and with a torque-speed (Keerthi, Sandya & Srinivas, 2016).

High-quality load sharing with a standard pressure and 200 gear angle (Tong, W. (2016). This

acceptable profile only fits gears with between 20 to 40 teeth. The pitches for this design are 6, 8,

10, 12, 100, 80, 64, 32, 20, 16, 24 and 48, representing the number of teeth per inch diameter.

The assumption is made for bulk UTS of the gears to undergo manufacturing to have 300 000 psi

and hardening for teeth up to 400BHN.

Because of low loading, the time that bears on shaft two can last is significantly higher

than usual. However, the stakes are very suitable in our scaled dimension, layout drawings and

geometry, therefore satisfying our requirements (Keerthi, Sandya & Srinivas, 2016). In that case,

we chose then for the gear design project. Keerthi, Sandya & Srinivas (2016) believe that the

same criteria apply for Shaft 3, 5; however, its life expectancies are considerable compared to the

ideal needs. Kissling, Stolz & Türich, (2019 found that the last spherical thrust for this bearing is

from SKF, and it was chosen for its suitable geometry, dimensional sketch and life expectancies.

A pitch's diameter has to have subscripts, but for others, like base and roots do not need

specifications.

We need to select a suitable ball bearing between angular and radial on an excellent

design of gear. Both have 1800rpm and a force for F1 and F2 as 1.5 and 1.2kN. Decisions and

assumptions are in place before designing. Such include;

Identification of objectives and constraint

a) The design will have a light-to-moderate consequence as a requirement

b). A conservative design that lasts for 10 hours every day at a continuous service is basic

c). It should have 99% reliability as an essential requirement

d). Angular ball bearing (𝛼 = 350) and a radial (𝛼 = 10) ought to be chosen

e). Ball-bearing life expectancy is inversely proportional with the 10.4 load power

f). The press-fit does not affect the bearing life.

Analysis of the design: one

From the above assumptions, the equivalent Radial load for both angular and radial ball bearings

is as follows

Ft/Fr = 1.25, Fe =Fr [1+1.115/ (Ft /Fr −0.35)]

=1.2[1+1.115(1.5 /1.20 −0.35)]

= 2.4 k N (radial bearing) = Fr [1+0.870/ (Ft/ Fr −0.68)]

=1.2[1+0.87/(1.5 1.20 −0.68)]

= 1.80 k N which is the angular bearing in this design

Justification

Prose

The result from finite elements for analysis undergoes comparison to indicate minor

deformation with the Hertz equation. Keerthi, Sandya & Srinivas, (2016) presents stress analysis
 GEAR DESIGN PROJECT 7

for the mating gears to determine the maximum amount of contact stress. Modelling of spur

gears continues, and assembly ends in a design modeller, which does the analytical work using

software (Keerthi, Sandya & Srinivas, 2016). According to Keerthi, Sandya & Srinivas (2016),

both finite elements and hertz equations analysis are easily comparable. From this pattern of

findings, it can conclude that the highest value of gear and steel deformation is very little.

Comparison and analyzing the available resources with materials useful for contact stress in gear

leads to better conclusions from two discoveries.

5 Evidence of a method

An engineer is designing on gearhead model is possible through the use of gear design

software. Due to undesirable effects, modern tools can compensate for the consequences

(Kissling, Stolz & Türich, 2019). According to Kissling, Stolz & Türich (2019), the absence of a

modern grinding machine can lead to compensation by the use of manufacturing twists. This

approach leads to discovery of an exact formula incase crowning generation occurs (Kissling,

Stolz & Türich, 2019). The equation is as follows. C= 8*Cβ*tan (Bb)*L0/b. using it, an engineer

can generate manufacturing twist through the software. The design decision is the best because

of automatic calculations have a three-dimensional display with contact analysis (Kissling, Stolz

& Türich, 2019). In that case, an expert can make decisions based on these outcomes for error

compensations. Also, it reduces the costs of designing by minimizing time consumption.

Furthermore, the conservative design is 99% reliable, has high life expectancy and moderate

impacts. For these reasons, the configuration is better than other possible methods due to the laid

advantages.
 GEAR DESIGN PROJECT 8

In summary, designing a gearhead requires a machine that saves time, reliable, moderate

impacts and high life expectancy. Also, it should give engineers ample time to generate a

manufacturing twist, which enables them to make decisions based on outcomes of error

compensation. A conservative design method is the most effective type for it allows moderate to

light impacts. The time that bearings on shaft two can last is significantly much high than usual.

However, they are found to be very suitable in our scaled dimension, layout drawings and

geometry. Configuration for his study is better than other possible methods due to the laid

advantages, including minimal errors, faster shaft efficiency, and higher reliability percentage.
 GEAR DESIGN PROJECT 9

References

Kissling, U., Stolz, U., & Türich, A. (2019, September). Combining gear design with manufacturing
process decisions. In International Conference on Gears, Garching/Munich, Germany (pp. 1532-
1544). https://www.powertransmission.com/issues/0620/gear-design.pdf

Tong, W. (2016, June). Mechanical design of electric machines. In 2016 IEEE Transportation
Electrification Conference and Expo (ITEC) (pp. 1-95). IEEE.
https://pdfs.semanticscholar.org/0052/d2527a87c207d46ea183fc7b24d39d4c2bcb.pdf

Keerthi, M., Sandya, K., & Srinivas, K. (2016). Static & dynamic analysis of spur gear using different
materials. International Research Journal of Engineering and Technology (IRJET), 3(01), 2395-
0056. https://www.academia.edu/download/54685759/IRJET-V3I1120.pdf