CHAPTER 4

DESIGN CALCULATION OF GEARBOX

4.1. Design Calculation for OKA-05 Gearbox

The design consideration and calculation of transmission are mostly dependent
upon the maximum torque of the input speed from the engine. The design work was
carried out on the gear trains of the rear wheel drive five speed manual transmission
for OKA-05 Jeep. In this gearbox, there are all together five forward speed and one
reverse. Among the five forward speeds, the fourth drive is the direct drive and the
final drive is the overdrive ratio.
To design analysis of OKA-05 gearbox, the required data are collected from
the existing transmission and assumptions are extracted from the theory of
automobile.
Industrial Zone South Okkalapa
Car type OKKALA Jeep (OKA-05)
Model code OKA-05
Engine type 4-cylinder-4-stroke-Diesel engine
Max: power 61 kW at 4200 rpm
Max: torque 162 Nm at 2400 rpm
Transmission 5 speed manual
1st gear ratio 3.600
2nd gear ratio 2.175
3rd gear ratio 1.635
4th gear ratio 1.000
5th gear ratio 0.938
Reverse gear ratio 3.960
Transmission type Rear wheel drive five speed manual
transmission
 28

4.1.1. Design Calculation of Fourth Speed Gear Pairs (G1 and G2)
In fourth speed, the power flow is straight through the transmission as shown
in Fig.4.1. This gear is a direct drive and the gear ratio is 1:1. But, in design
calculation of 4th speed gear pair G1 and G2, and velocity ratio V.R4 is 1.5.

1stgear reverse
rd
2ndgear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.1. Fourth Gear Mesh

6150 OQT400 alloy steel heat-treated material

Type of gear = helical gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
E = 207×10 3N/mm2
Helix angle, ψ = 30°
Velocity ratio, V.R4 = 1.5

Pinion speed,
Np = 4200 rpm
Number of teeth on pinion, Tp = 26
Pressure angle = 20° full depth involute
Assuming medium shock conditions and 8-10 hours of service per day, the
service factor (Cs) from Table A-5 is given by 1.54.
Design power = 61kW×Cs= 61×1.54= 94kW
The torque transmitted by the pinion,
 29

3
P×60 94×10 ×60
T= = =213 .722Nm=213722 Nmm
2 π N p 2×π×4200
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design is based on the pinion.
Formative or equivalent number of teeth,
Tp 26
T E= 3
= =40
cos ψ cos3 30
0 . 912
0 .154−
y = TE ( ∵20° full depth involute system )
0 . 912
0 .154−
= 40
= 0.1312
Let m = Module in mm, and
Dp = Pitch circle diameter of the pinion in mm.
Tangential tooth load on the pinion,
T 2T 2T
WT= = =
( ∵ D P=mT P )
D P /2 D P m×T P
2×213722 16440
=
= m×26 m
Peripheral velocity,
πD P N P π m T P N P
=
v = 60 60
πm×26×4200
= 60
= 5718 m mm/s = 5.718 m m/s
Velocity factor,
15 15
=
Assume Cv = 15+v 15+5 .718m
Tangential tooth load,

WT =
σ O CV b π m y

16440
m =
455× (1515+5. 718m )×12 .5×π ×m ×0 .1312
2

(
∵ b=12.5 m )
 30

2
16440 35164 m
m = 15+5 .718 m
m = 2.37 mm say 2.5 mm
Face width,
b =12. 5 m=12 .5×2 .5=31 mm
Pitch circle diameter of the pinion,
D p =m×T p =2 .5×26=65 mm
Velocity ratio,
N p 4200
V . R 4= = =1 .5
Ng N g
Ng = 2800 rpm
Tg
V . R 4= =1. 5
Tp
Tg = 1.5×26 = 39
Pitch circle diameter of the gear,
Dg =m×T g =2. 5×39=98 mm
16440 16440
=6576 N
Tangential tooth load, WT = m = 2. 5
πD p N p π×65×10−3 ×4200
= =14 .29 m/s
v = 60 60
Dynamic tooth load,
21×v (bCcos2 ψ +W T )cos ψ
W D=W T +
21×v+ √ (bCcos 2 ψ +W T )
m = 2.5 mm, Tooth error = 0.01 (From Figure B-2)
C = 110 N/mm (From Table A-3)
21×14 . 29×( 31×110×cos2 30+ 6576)×cos30
W D=6576+
21×14 . 29+ √ (31×110×cos 2 30+6576 )
= 12575.3 N
Static tooth load,

WS =
σe b π m y

= 700×31×π ×2 .5×0 .1312

= 22361 N
 31

Wear tooth load,

D pb Q K
WW=
cos2 ψ
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2
1 1 2
K=
2
σ es sin ϕ N
( +
Ep Eg )= 1613 2×sin17. 5×
207×103
1. 4 1. 4
= 5.399 N/mm2
2×V . R 4 2×1 .5
= =1. 2
Q = V . R4 +1 1 .5+1

65×31×5 .399×1. 2
WW=
cos2 30 =17406.4 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×2.5=2.5 mm
Dedendum = 1.25m=1.25×2.5=3.125 mm
D g + D p 98+ 65
= =82
C = 2 2 mm

4.1.2. Design Calculation of First Speed Gear Pair (G7 and G8)
In this position, the transmitted power passes through the main drive gear(G1)
of input shaft and constant mesh counter gear(G2) to the first drive gear(G8) on
counter shaft and then to first driven gear(G1) on main shaft as shown in Fig.4.2. 1 st
gear ratio is V.R4×V.R1= 3.6 and V.R4 =1.5. So, first speed gear pair velocity ratio,
V.R1 is 2.4.
6150 OQT400 alloy steel heat-treated material
Type of gear = helical gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
 32

E = 207×10 3N/mm2
Helix angle, ψ = 30°
Velocity ratio, V.R1 = 2.4

Pinion speed,
Np = 2800 rpm
Number of teeth on pinion, Tp = 12
Design power = 94kW
Pressure angle = 20° full depth involute

1stgear reverse
nd
rd
2 gear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.2. First Gear Mesh

The torque transmitted by the pinion,

3
P×60 94×10 ×60
T= = =320 .584 Nm=320584 Nmm
2 π N p 2×π ×2800
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Formative or equivalent number of teeth,
Tp 12
T E= 3
= =18 . 5
cos ψ cos3 30
0 . 912
0 .154−
y = TE ( ∵20° full depth involute system )
0 . 912
0 .154−
= 18 . 5
= 0.105
Let m = Module in mm, and
 33

Dp = Pitch circle diameter of the pinion in mm.

Tangential tooth load on the pinion,
T 2T 2T
WT= = =
( ∵ D P=mT P )
D P /2 D P m×T P
2×320584
= m×12
53431
= m
Peripheral velocity,
πD P N P π mT P N P
=
v = 60 60
πm×12×2800
= 60
= 1759 m mm/s = 1.759 m m/s
Velocity factor,
6 6
=
Assume Cv = 6 +v 6+1 .759 m
Tangential tooth load,

WT =
σ O CV b π m y

53431
m =
455× ( 6+1 .6759 m )×12 .5×m ×π ×0 .105
2

(
∵ b=12.5 m )
2
53431 11257 m
m = 6 +1. 759 m
m = 3.95 mm say 4 mm
Face width,
b =12. 5 m=12 .5×4=50 mm
Pitch circle diameter of the pinion,
D p =m×T p =4×12=48 mm
Velocity ratio,
N p 2800
V . R1 = = =2 . 4
Ng N g
 34

Ng = 1167 rpm
Tg
V . R1 = =2. 4
Tp
Tg = 2.4×12= 29
Pitch circle diameter of the gear,
Dg =m×T g =4×29=116 mm
53431 53431
=13358 N
Tangential tooth load, WT = m = 4
πD p N p π×48×10 -3×2800
= =7 . 037 m/s
v = 60 60
Dynamic tooth load,
2
21×v (bCcos ψ +W T )cos ψ
W D=W T +
21×v+ √ (bCcos 2 ψ +W T )
m = 4 mm, Tooth error = 0.0125 (From Figure B-2)
C = 138 N/mm (From Table A-3)
21×7 .037×( 50×138×cos 2 30+13358 )×cos30
W D=13358+
21×7 .037 + √ (50×138×cos 2 30+13358)
= 21712 N
Static tooth load,

WS =
σe b π m y

= 700×50×π×4×0 .105
= 46181 N
Wear tooth load,
D pb Q K
WW=
cos2 ψ
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2
 35

1 1 2
K=
2
σ es sin ϕ N
( +
Ep Eg )=1613 ×sin17. 5×207×10
2
3

1. 4 1. 4
= 5.399 N/mm2
2×V . R1 2×2. 4
= =1. 412
Q = V . R1 +1 2 . 4+ 1

48×50×5 . 399×1 . 412

WW=
cos2 30
= 24395 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×4=4 mm
Dedendum = 1.25m=1.25×4=5mm
D g + D p 116+48
= =82
C = 2 2 mm

4.1.3. Design Calculation of Second Speed Gear Pairs (G5 and G6)
In this position, the transmitted power passes through the main drive gear(G1)
of input shaft and constant mesh counter gear(G2) to the second drive gear(G6) on
counter shaft and then to second driven gear(G5) on main shaft. 2 nd gear ratio is V.R4
×V.R2= 2.175. So, second speed gear pair velocity ratio, V.R2 is 1.45.

1stgear reverse
nd
rd
2 gear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.3. Second Gear Mesh

6150 OQT400 alloy steel heat-treated material

 36

Type of gear = helical gear

BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
E = 207×10 3N/mm2
Helix angle, ψ = 30°
Velocity ratio, V.R2 = 1.45

Pinion speed,
Np = 2800 rpm
Number of teeth on pinion, Tp = 19
Design power = 94kW
Pressure angle = 20 ° full depth involute
The torque transmitted by the pinion,
3
P×60 94×10 ×60
T= = =320 .584 Nm=320584 Nmm
2 π N p 2×π ×2800
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Formative or equivalent number of teeth,
Tp 19
T E= 3
= =29 . 3
cos ψ cos3 30
0 . 912
0 .154−
y = TE ( ∵20° full depth involute system )
0 .912
0 .154−
= 29 . 3
= 0.123
Let m = Module in mm, and
Dp = Pitch circle diameter of the pinion in mm.
Tangential tooth load on the pinion,
T 2T 2T
WT= = =
( ∵ D P=mT P )
D P /2 D P m×T P

2×320584 33746
=
= m×19 m
 37

Peripheral velocity,
πD P N P π mT P N P
=
v = 60 60

πm×19×2800
= 60
= 2786 m mm/s = 2.786 m m/s
Velocity factor,
6 6
=
Assume Cv = 6 +v 6+2 .786 m
Tangential tooth load,

WT =
σ O CV b π m y

33746
m =
455× ( 6+2 .6786 m )×12 .5×πm ×0 . 123
2

∵ b=12 .5m )

33746 13186 m 2
m = 6 +2. 786 m
m = 3.41 mm say 3.5 mm
Face width,
b =12. 5 m=12 .5×3 .5=44 mm
Pitch circle diameter of the pinion,
D p =m×T p=3 .5×19= 67 mm
Velocity ratio,
N p 2800
V . R2 = = =1 . 45
Ng N g
Ng = 1931 rpm
Tg
V . R2 = =1. 45
Tp
Tg = 1.45×19=28
Pitch circle diameter of the gear,
Dg =m×T g =3 .5×27= 95 mm
 38

33746 33746
=9642 N
Tangential tooth load, WT = m = 3 .5
πD p N p π×67×10-3 ×2800
= =9 . 823 m/s
v = 60 60
Dynamic tooth load,
2
21×v (bCcos ψ +W T )cos ψ
W D=W T +
21×v+ √ (bCcos 2 ψ +W T )

m = 3.5 mm, Tooth error = 0.01(From Figure B-2)

C = 110 N/mm (From Table A-3)

21×9 . 823×( 44×110×cos 2 30+9642)×cos30

W D=9642+
21×9 . 823+ √ (44×110×cos 2 30+9642 )
= 17017 N
Static tooth load,

WS =
σe b π m y

= 700×44×π ×3 .5×0 . 123

= 41656 N
Wear tooth load,
D pb Q K
WW=
cos2 ψ
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2
1 1 2
K=
σ 2es sin ϕ N
( +
Ep Eg )=1613 ×sin17. 5×207×10
2
3

1. 4 1. 4
= 5.399 N/mm2
2×V . R2 2×1. 45
= =1 . 184
Q = V . R2 +1 1 . 45+1

67×44×5 .399×1. 184

WW=
cos2 30
 39

= 25126 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×3.5=3.5 mm
Dedendum = 1.25m=1.25×3.5=4.375mm
D g + D p 98+67
= =82
C = 2 2 mm

4.1.4. Design Calculation of Third Speed Gear Pair (G3 and G4)
In this position, the transmitted power passes through the main drive gear(G1)
of input shaft and constant mesh counter gear(G2) to the third drive gear(G4) on
counter shaft and then to third driven gear(G3) on main shaft. 3 rd gear ratio is V.R4×
V.R3= 1.635. So, third speed gear pair velocity ratio, V.R3 is 1.09.
6150 OQT400 alloy steel heat-treated material
Type of gear = helical gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2

1stgear reverse
rd
2ndgear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.4. Third Gear Mesh

E = 207×10 3N/mm2
Helix angle, ψ = 30°
Velocity ratio, V.R3 = 1.09

Pinion speed,
Np = 3052 rpm
 40

Number of teeth on pinion, Tp = 31

Design power = 94kW
Pressure angle = 20° full depth involute
The torque transmitted by the pinion,
3
P×60 94×10 ×60
T= = =294 . 113 Nm=294113 Nmm
2 π N p 2×π ×3052
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Formative or equivalent number of teeth,
Tp 31
T E= 3
= =48
cos ψ cos3 30
0 . 912
0 .154−
y = TE ( ∵20° full depth involute system )
0 . 912
0 .154−
= 48
= 0.135
Let m = Module in mm, and
Dp = Pitch circle diameter of the pinion in mm.
Tangential tooth load on the pinion,
T 2T 2T
WT= = =
D P /2 D P m×T P ( ∵D P =m .T P )
2×294113 18975
=
= m×31 m
Peripheral velocity,
πD P N P π mT P N P
=
v = 60 60
πm×31×3052
= 60
= 4954 m mm/s = 4.954 m m/s
Velocity factor,
15 15
=
Assume Cv = 15+v 15+ 4 . 954 m
Tangential tooth load,

WT =
σ O CV bπ my
 41

18975
m =
455× (1515+ 4 . 954 m )×12 .5×πm ×0 . 135
2

(
∵ b=12.5 m )
2
18975 36182 m
m = 15+4 .954 m
m = 2.42 mm say 2.5 mm
Face width,
b =12. 5 m=12 .5×2 .5=31 mm
Pitch circle diameter of the pinion,
D p =m×T p =2 .5×31=78 mm
Velocity ratio,
N p 3052
V . R3 = = =1 .09
Ng N g
Ng = 2800 rpm
Tg
V . R3 = =1 .09
Tp
Tg = 1.09×31= 34
Pitch circle diameter of the gear,
Dg =m×T g =2. 5×34=85 mm
18975 18975
=7590 N
Tangential tooth load, WT = m = 2. 5
πD p N p π×78×10-3×3052
= =12 . 46 m/s
v = 60 60
Dynamic tooth load,
21×v (bCcos2 ψ +W T ) cos ψ
W D=W T +
21×v+ √ (bCcos 2 ψ +W T )
m = 2.5 mm, Tooth error = 0.01(From Figure B-2)
C = 110 N/mm (From Table A-3)
21×12. 46×( 31×110×cos2 30+7590 )×cos30
W D=7590+
21×12. 46+ √(31×110×cos 2 30+7590)
= 13935 N
Static tooth load,
 42

WS =
σe b π m y

= 700×31×π ×2 .5×0 .135

= 23008 N
Wear tooth load,
D pb Q K
WW=
cos2 ψ
tan φ N =tan φ×cos ψ
φ N = tan-1 (tan20×cos30)
=17 .5 °
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2
1 1 2
K=
2
σ es sin ϕ N
( +
Ep Eg ) =
1613 2×sin17. 5×
207×103
1. 4 1. 4
= 5.399 N/mm2
2V . R3 2×1 . 09
= =1. 043
Q = V . R 3 +1 1 .09+1
78×31×5. 399×1. 043
WW =
cos2 30
= 18155 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×2.5=2.5 mm
Dedendum = 1.25m=1.25×2.5=3.125mm
D g + D p 85+ 78
= =82
C = 2 2 mm

4.1.5. Design Calculation of Fifth Speed Gear Pair (G9 and G10)
In this position, the transmitted power passes through the main drive gear(G1)
of input shaft and constant mesh counter gear(G2) to the fifth drive gear(G10) on
counter shaft and then to fifth driven gear(G9) on main shaft. 5 th gear ratio is V.R4×
0.625= 0.938 because this gear is actually an overdrive. But, in design calculation of
5th speed gear pair which velocity ratio, V.R5 is 1.6.
 43

6150 OQT400 alloy steel heat-treated material

Type of gear = helical gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
E = 207×10 3N/mm2
Helix angle, ψ = 30°
Velocity ratio, V.R5 = 1.6

Pinion speed,
Np = 4480 rpm
Number of teeth on pinion, Tp = 25

1stgear reverse
rd
2ndgear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.5. Fifth Gear Mesh

Design power = 61kW×Cs= 61×1.54= 94kW
∘
Pressure angle = 20 full depth involute
The torque transmitted by the pinion,
3
P×60 94×10 ×60
T= = =200 .365 Nm=200365 Nmm
2 π N p 2×π×4480
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Formative or equivalent number of teeth,
Tp 25
T E= 3
= =38 . 5
cos ψ cos3 30
 44

0 . 912
0 .154−
y = TE ( ∵20° full depth involute system )
0 .912
0 .154−
= 38 . 5
= 0.1303
Let m = Module in mm, and
Dp = Pitch circle diameter of the pinion in mm.
Tangential tooth load on the pinion,
T 2T 2T
WT= = =
( ∵D P =m .T P )
D P /2 D P m×T P

2×200365 16029 .2
=
= m×25 m
Peripheral velocity,
πD P N P π m TP NP
=
v = 60 60
πm×25×4480
= 5864 m mm/s = 5. 864 m m/s
= 60
Velocity factor,
15 15
=
Assume Cv = 15+v 15+5 . 864 m
Tangential tooth load,

WT =
σ O CV b π m y

16029.2
m =
455× (1515+5. 864 m )×12 .5×πm ×0 . 1303
2

(
∵ b=12 .5m )
16029.2 34923 m 2
m = 15+5 .864 m
m = 2.37 mm say 2.5 mm
Face width,
b =12. 5m=12 .5×2 .5=31 mm
Pitch circle diameter of the pinion,
D p =m×T p =2 .5×25=63 mm
 45

Velocity ratio,
N p 4480
V . R5 = = =1. 6
Ng N g
Ng = 2800 rpm
Tg
V . R5 = =1 .6
Tp
Tg = 1.6×25= 40
Pitch circle diameter of the gear,
Dg =m×T g =2. 5×40=100 mm
16029.2 16029. 2
= 6412 N
Tangential tooth load, WT = m = 2.5
πD p N p π×63×10-3×4480
= = 15 m/s
v = 60 60
Dynamic tooth load,
2
21×v (bCcos ψ +W T )cos ψ
W D=W T +
21×v+ √ (bCcos 2 ψ +W T )
m = 2.5 mm, Tooth error = 0.01 (From Figure B-2)
C = 110 N/mm (From Table A-3)
21×15×( 31×110×cos2 30+6412)×cos30
W D=6412+
21×15+ √ (31×110×cos 2 30+6412)
= 12384 N
Static tooth load,

WS =
σe b π m y

= 700×31×π ×2 .5×0 .1303

= 22207 N
Wear tooth load,
D pb Q K
WW=
cos2 ψ
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
σ es = (2.8×BHN) -70 N/mm2
 46

= (2.8×601)-70
= 1613 N/mm2
1 1 2
K=
σ 2es sin ϕ N
( +
Ep Eg )=1613 ×sin17. 5×207×10
2
3

1. 4 1. 4
= 5.399 N/mm2
2V . R5 2×1 .6
= =1. 231
Q = V . R5 +1 1 .6+1
63×31×5 .399×1. 231
WW=
cos2 30
= 17307 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×2.5=2.5 mm
Dedendum = 1.25m=1.25×2.5=3.125 mm
D g + D p 100+63
=
C = 2 2 = 82 mm

4.1.6 Design Calculation of Reverse Speed Gear Pair (Pinion G13 to Idler Gear
G12)
Reverse gear ratio is V.R4 ×V.Rr1 ×V.Rr2= 3.96.
6150 OQT400 alloy steel heat-treated material
Type of gear = spur gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
E = 207×10 3N/mm2
Velocity ratio, V.Rr1 = 2.2
 47

1stgear reverse
rd
2ndgear gear
4th gear 3 gear 5thgear
1 3 5 7 11 9

12

8 13 10
2 4 6

Fig.4.6. Reverse Gear Mesh

Pinion speed,
Np = 2800 rpm
Number of teeth on pinion, Tp = 13
Power = 61 kW
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Let m = Module in mm, and
Dp= Pitch circle diameter of the pinion in mm.
Pitch line velocity,
πD P N P π m TP NP
=
v = 60 60 ( ∵D P =m .T P )
π ×m×13×2800
= 60
= 1906 m mm/s = 1.906 m m/s
Assuming medium shock conditions and 8-10 hours of service per day, the
service factor (Cs) from Table A-5 is given by 1.54.
Design tangential tooth load,
P
W T = ×C s
v
61×1000
= ×1 .54
1 . 906 m
 48

32004
= m N
Velocity factor,
3 3
=
Assume Cv = 3+v 3+1. 906 m
Tooth form factor,
0 . 912
0 .154−
y = T P , ( for 20°full depth involute system )

0 .912
0 .154−
= 13
= 0.114
Tangential tooth load,

WT =
σ O CV b π m y

32004 3
m =
455× ( 3+1 . 906 m)×12 .5×πm2 ×0 . 114
(
∵ b=12 .5m )
2
32004 6111m
m = 3+1.906 m
m = 3.48 = 3.5 mm
Face width,
b =12. 5m=12 .5×3 .5=44 mm
Pitch circle diameter of the pinion,
D p =m×T p =3 .5×13=46 mm
Velocity ratio,
N p 2800
V . R r1= = =2 .2
Ng N g
Ng = 1273 rpm
Tg
V . R r1= =2. 2
Tp
Tg = 2.2 ×13= 29
Pitch circle diameter of the gear,
Dg =m×T g =3 .5×29=102 mm
 49

32004 32004
=9144 N
Tangential tooth load, WT = m = 3 .5
πD p N p π ×46×10−3 ×2800
= =6 . 744 m/s
v = 60 60
Dynamic tooth load,
21×v ( bC+W T )
W D=W T +
21×v+ √ ( bC+W T )

m = 3.5 mm, Tooth error = 0.01 (From Figure B-2)

C = 110 N/mm (From Table A-3)
21×6 . 744×( 44×110+9144 )
W D=9144 +
21×6 . 744+ √(44×110+9144 )
= 16765 N
Static tooth load,

WS =
σe b π m y

= 700×44×π ×3 .5×0 . 114

= 38608 N
Wear tooth load,
W W =D p b Q K
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2

1 1

K=
σ 2es sin ϕ
( +
Ep Eg )
1.4
2
16132 ×sin20×
207×103
= 1.4 = 6.141 N/mm2
2V . R r1
Q = V . Rr1 +1
2×2. 2
=1 .375
= 2. 2+1
 50

W W =46×44×6 . 141×1 .355

= 16842 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×3.5=3.5 mm
Dedendum = 1.25m=1.25×3.5=4.375 mm
4.1.7. Design Calculation of Reverse Speed Gear Pair (Idler G12 to Gear G11)
6150 OQT400 alloy steel heat-treated material
Type of gear = spur gear
BHN = 601
σo = 455 N/mm2
σe = 700 N/mm2
E = 207×10 3N/mm2
Velocity ratio, V.Rr2 = 1.2

Pinion speed,
Np = 1273 rpm
Number of teeth on pinion, Tp = 29
Power = 61 kW
Since both pinion and gear are made of the same material. Therefore the pinion is
weaker. So, the design based on the pinion.
Let m = Module in mm, and
Dp= Pitch circle diameter of the pinion in mm.
Pitch line velocity,
πD P N P π mT P N P
=
v = 60 60 ( ∵D P =m .T P )
π ×m×29×1273
= 60
= 1933 m mm/s = 1.933 m m/s
Assuming medium shock conditions and 8-10 hours of service per day, the
service factor (Cs) from Table A-5 is given by 1.54.
Design tangential tooth load,
P
W T = ×C s
v
 51

61×1000
= ×1 .54
1 . 933 m
31557
= m N
Velocity factor,
3 3
=
Assume Cv = 3+v 3+1. 933 m
Tooth form factor,
0 . 912
0 .154−
y = T P , ( for 20°full depth involute system )

0 .912
0 .154−
= 29
= 0.123
Tangential tooth load,

WT =
σ O CV b π m y

31557 3
m =
455× ( )
3+1 . 933 m
×12 .5×πm2 ×0 . 123
(
∵ b=12 .5m )
2
31557 6593 m
m = 3+1. 933m
m = 3.46 mm say 3.5 mm
Face width,
b =12. 5m=12 .5×3 .5=44 mm
Pitch circle diameter of the pinion,
D p =m×T p =3 .5×29=102 mm
Velocity ratio,
N p 1273
V . R r2= = = 1. 2
Ng N g
Ng = 1061 rpm
Tg
V . R r2= =1. 2
Tp
Tg = 1.2×29 = 35
 52

Pitch circle diameter of the gear,

Dg =m×T g =3 .5×35=123 mm
31557 31557
=9016N
Tangential tooth load, WT = m = 3 .5
πD p N p π×102×10−3 ×1273
= = 6 . 799 m/s
v = 60 60
Dynamic tooth load,
21×v ( bC+W T )
W D=W T +
21×v+ √ ( bC+W T )
m = 3.5 mm, Tooth error = 0.01 (From Figure B-2)
C = 110 N/mm (From Table A-3)
21×6 . 799×( 44×110+9016 )
W D=9016 +
21×6 . 799+ √ (44×110+9016 )
= 16611 N
Static tooth load,

WS =
σe b π m y

= 700×44×π ×3 .5×0 . 123

= 41656 N
Wear tooth load,
W W =D p b Q K
σ es = (2.8×BHN) -70 N/mm2
= (2.8×601)-70
= 1613 N/mm2
1 1

K=
σ 2es sin ϕ
( +
Ep Eg )
1.4
2
16132 ×sin20×
207×103
= 1.4 = 6.141 N/mm2
2V . R r2
Q = V . Rr2 +1
2×1 .2
= =1 . 091
1 .2+1
 53

W W =102×44×6. 141×1 . 091

= 30069 N
WW, WS > WD. So the design is satisfied.
Addendum = 1m = 1×3.5=3.5 mm
Dedendum = 1.25m=1.25×3.5=4.375 mm
123+46
= 85 mm .
Center distance between G11 and G13 is 2

4.2. Results of Gear Design Calculation

The results of design calculation and the data compared between the
calculated design and existing design are shown in Table 4.1. and Table 4.2.
respectively.
Table 4.1. Results Data for Gear Design Calculation

1st 2nd 3rd 4th 5th Reverse

Gear pair
Gear ratio 3.600 2.175 1.635 1.000 0.938 3.960

G7 G6 G5 G3 G4 G1 G2 G9 G10 G13 G12 G11

Gears G8
No. of
12 29 19 28 31 34 26 39 25 40 13 29 35
teeth
Module
4 4 3.5 3.5 2.5 2.5 2.5 2.5 2.5 2.5 3.5 3.5 3.5
(mm)
Pitch
circle dia: 48 116 67 98 78 85 65 98 63 100 46 102 123
(mm)
Face width
50 50 44 44 31 31 31 31 31 31 44 44 44
(mm)
Addendum
4 3.5 2.5 2.5 2.5 3.5
(mm)
Dedendum
5 4.375 3.125 3.125 3.125 4.375
(mm)

Table 4.2. Comparison of Calculated Result Data and Existing Data

Details
Results of Design Calculation Existing Design

No. of Dia: Face No. of Dia: Face

 54

Width Width
teeth (mm) teeth (mm)
(mm) (mm)
st
1 Gear 29/12 116/48 50 34/14 109/51 48
2nd Gear 28/19 98/67 44 35/25 91/68 38
3rd Gear 34/31 85/78 31 35/33 82/76 31
4th Gear 39/26 98/65 31 47/32 93/63 31
5th Gear 40/25 100/63 31 57/33 98/59 32
Reverse 123/102/
35/29/13 44 39/31/14 147/86/41 38
Gear 46
4.3. Design Calculation of Shafts
In manual transmission, shafts are also the important parts of the design
portion. The shaft design calculations are mainly based on the maximum shear stress
theory. In shaft design calculation, input shaft, first speed positions of counter and
output shaft, idler shaft are included. The weights of gear acting on each shaft are also
calculated and shown in Table 4.3.

Table 4.3. Calculation of Gears Weight

2
W G=0. 00118 T G b m

TG b (m) W(exist) W(Cal)

No. of teeth Face Width Weight Weight

No.1 Gear 26 0.031 7.316 N 5.944 N

No.2 Gear 39 0.031 10.75 N 8.916 N

No.3 Gear 31 0.031 7.545 N 7.087 N

No.4 Gear 34 0.031 8.002 N 7.773 N

No.5 Gear 28 0.044 15.90 N 17.81 N

No.6 Gear 19 0.044 22.26 N 12.08 N

No.7 Gear 29 0.050 32.096 N 27.38 N

No.8 Gear 12 0.050 13.22 N 11.34 N

No.9 Gear 25 0.031 7.545 N 5.716 N

No.10 Gear 40 0.031 13.03 N 9.145 N

 55

No.11 Gear 35 0.044 24.80 N 21.625 N

No.12 Gear 29 0.044 19.72 N 17.81 N

No.13 Gear 13 0.044 8.904 N 8.268 N

4.3.1. Design Calculation of Input Shaft

Shaft speed = 4200rpm
D1 = 65 mm, W1 = 5.944 N
L = 218 mm
Helix angle = 30°
Pressure angle = 20°
Design power = 94 kW
Weight of clutch disc = 1.724 kg×9.81= 16.91N
For torsional moment of shaft, Mt
9550×kW 9550×94
Mt = = = 218
rpm 4200 Nm
To find tangential force,
2Mt 2×218
F t1 = = =6708
D1 65×10-3 N
To find axial force and radial force,
Fa1 = F t1 tanψ = 6708×tan30 = 3873 N
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
F r1 = F t1 tan φ N =6708×tan17. 5 =2115 N
For Vertical Moment,

Taking moment about A, ∑MA ( +) = 0 (clockwise positive)

(−W c ×0 .137 )+(( W 1−F r1 )×0 . 025 )+( R B ×0 . 0 45 )=0
(−16 . 91×0 .137 )+((5 . 944−2115)×0 . 0 25)+( RB×0. 045 )=0
RB =1223 N

∑ F y =0(↑+)
 56

F r1−W C −R A−R B−W 1 =0

2115−16 . 91−1223−5 . 944−R A =0
R A =869 N
For Horizontal Moment,

Taking moment about A, ∑ MA ( +) = 0 (clockwise positive)

( F t1×0. 025 )−( R B ×0 .045) = 0
(6708×0 . 025 )−( R B ×0 . 045)=0
RB = 3727 N

WC
1
C A B
Fr
137mm 25mm 20mm
Ft
WC
RA W1
RB
(a) V.L.D
Fr1

Ft1
(b) H.L.D
RB
RA

(c) V.B.M.D
2.317

24.5

75

(d)H.B.M.D

78.3

2.317
(e)C.B.M.D

Fig.4.7. Loading and Bending Moment Diagram of Input Shaft.

 57

∑ F y (↑+)=0
R A +R B − F t1 =0
R A = − 3727+6708
= 2981 N
For Vertical Bending Moment,
M AV =(−W C ×0 . 137)=(−16 . 91×0 . 137)=−2. 317 Nm
M 1V =(−W C ×0 .162 ) −(R A×0 . 0 25)
=(−16. 91×0 . 162) −(869×0. 0 25 )
=−24 .5 Nm
For Horizontal Bending Moment,
M AH =0
M 1H = ( R A ×0 . 025 )= (2981×0 . 0 25) = 75 Nm
From Vertical and Horizontal Bending Moment,

M A=√ ( M AV )2 +( M AH )2 =√ 2. 3172 +02 =2. 317 Nm

M 1= √ (M 1V )2 +( M 1H )2 =√ 24 .5 2 +752 =79 Nm
M b( max )=79Nm
Maximum bending moment,
Maximum bending moment occurs at gear with keyway,
S s =0 . 18×Su ×0 . 75=0. 18×2170×0 . 75=293 Mpa
S s =0 .3×S y×0. 75=0 .3×1860×0.75=419 Mpa

Choose,
S s =293Mpa
For rotating shaft with load suddenly applied, heavy shock
K b =2,Kt =1 . 5 (From Table A-6)

d
k = =0. 25d
4
L= 218 mm= 0.218 m
L
<115
Assume, k
1
α=
1−0 . 0044 ( Lk )
 58

1 1 d
α= = =
4L 4×0 .218 d−3 .8368×10−3
1−0 . 0044 ( )
d
1−0 . 0044 ( d )

For solid shaft subjected to combine bending, torsion and axial load.

αF a d 2
d 3
=
16
πS s √( Kb M b+
8 )
+( K t M t )2

2
3873d 2

d
d 3
=
16
π ×293×10
6

= 0.019m= 19mm
√( 2×79+ -3
8(d-3. 8368×10 )
+(1 .5×218 )2
)
Used d = 20 mm
4.3.2. Calculation of First Speed Position of Counter Shaft
Shaft speed = 2800 rpm
6150 OQ T400 heat-treated alloy steel material
S u =2170 Mpa, S y =1860 Mpa
Design power = 94 kW
D2 = 98 mm
D8 = 48 mm

Helix angle of D2, ψ = 30°

Helix angle of D8, ψ = 30°
W2 = 8.916 N
W4 = 7.773 N
W6 = 12.08 N
W8 = 11.34 N
W 10 = 9.145 N
W 13 = 8 .268 N
For torsional moment of shaft, Mt
 59

9550×kW 9550×94
Mt = = = 321
rpm 2800 Nm
For gear (2),
To find tangential force,
2Mt 2×321
F t2 = = = 6551
D2 98×10-3 N
To find axial force and radial force,
Fa2 = F t2 tanψ = 6551×tan30 = 3782 N
tan φ N =tan φ×cosψ
φ N = tan -1 (tan20×cos30)
=17 .5 °
F r2 = F t2 tan φ N =6551×tan17 . 5 =2066 N
For gear (8),
To find tangential force,
2Mt 2×321
F t8 = = = 13375
D8 0 . 048 N
To find radial force,
F r8 = F t8 tan φ N = 13375×tan17. 5 = 4217 N
To find axial force,
Fa8 = F t8 tan ψ = 13375×tan30 = 7722 N
For Vertical Moment,

Taking moment about A, ∑ MA ( +) = 0 (clockwise positive)

(−R B ×0 . 228 )+(W 10×0 . 2)+(W 13×0 . 152)+((W 8 +F r8 )×0 .123 )+(W 6 ×0 .076 )
+(W 4 ×0 . 071)+((W 2 +F r2 )×0 .024 )=0
(−R B ×0 . 228 )+(9 .145×0 .2 )+(8 . 268×0 . 152)+((11.34 +4217 )×0 . 123)
+(12 . 08×0 . 076 )+(7 .773×0 . 071)+((8. 916+2066)×0 .024 )=0
RB =2519 .5 N

∑ F y (+↑)=0
R A +R B−(W 2 +F r2 )−W 4 −W 6−(W 8 +F r8 )−W 13−W 10=0
R A +2519 .5−( 8. 916+2066)−7. 773−12. 08−(11.34 +4217 )−8. 268−9 .145=0
R A = 3821 N
 60

For Horizontal Moment,

Taking moment about A, ∑ MA ( +) = 0 (clockwise positive)

(−R B×0 . 228 )−( F t2 ×0 . 024)+( F t8×0. 123 )= 0
(−R B×0 . 228 ) −(6551×0 .024 )+(13375×0 . 123)= 0
RB =6526 N

∑ F y (+↑)=0
R A +R B +F t2−F t8 =0
R A =−6526−6551+13375=298 N
For Vertical Bending Moment,
M 2V =R A×0 . 024=3821×0 . 024=92 Nm

M 4V = (R A ×0. 071)−((W 2 +F r2 )×0 . 047)

=(3821×0. 071 )−((8 .916+2066)×0 .047 )
= 174 Nm
-3
M 6V =(R A×0. 076 )−((W 2 +F r2 )×0 . 052)−(W 4 ×5×10 )

¿(3821×0. 076 )−((8 . 916+2066 )×0 .052)−(7 .773×5×10 -3 )

¿182. 5Nm
M 8V=( R A ×0 .123 )−((W 2 +F r2 )×0 . 099)−(W 4 ×0. 052 )−(W 6 ×0 .047 )

=(3821×0 .123 )−((8 . 916+2066 )×0 .099)−(7 .773×0 . 052)

−(12 .08×0 . 047 )
= 264 Nm
M 13V =( R A×0 . 152)−((W 2 +F r2 )×0 . 128)−(W 4 ×0. 081 )−(W 6 ×0 .076 )
−(( W 8. +F r8 )×0 .029 )

=(3821×0. 152)−(( 8. 916+2066)×0. 128 )−(7 . 773×0. 081)

−(12 .08×0 . 076 )−(( 11. 34+4217 )×0 . 029)
= 191 Nm
M 10V =( R A ×0 . 2)−((W 2 +F r2 )×0 . 176)−(W 4 ×0 .129 )−(W 6 ×0 .124 )
−((W 8 +F r8 )×0 . 077)−(W 13 ×0 .048 )
=(3821×0. 2 )−((8. 916+2066)×0 .176 )−(7. 773×0 .129 )
−(12 .08×0 . 124 )−((11. 34+4217 )×0 . 077 )−(8 . 268×0. 048 )
=71 Nm
For Horizontal Bending Moment,
 61

M 2H=(R A×0. 024 )=(298×0. 024 ) =7 .152 Nm

M 4H = ( R A ×0 . 071)+(F t2 ×0 . 047 )
=(298×0 . 071)+(6551×0. 047 )
=329 Nm
M 6H = ( R A ×0 . 076)+(F t2×0 . 052)

= (298×0 . 076 )+(6551×0. 052)

= 363 Nm
M 8H = ( R A ×0 . 123)+( F t2 ×0 . 099)
= (298×0 .123 )+(6551×0 . 099 )
= 685Nm
M 13H = (R A ×0 . 152)+( F t2 ×0 .128 )−( F t8×0. 029 )
= (298×0 .152)+(6551×0 . 128)−(13375×0 . 029 )
=496 Nm
M 10H = (R A×0. 2) +(F t2×0 . 176)−( F t8 ×0. 077)
=(298×0 .2 ) +(6551×0.176 )−(13375×0 . 077)
=183 Nm
From Vertical and Horizontal Moment,

M 2= √ (M 2V )2 +( M 2H )2 =√ 922 +7 . 1522 =92. 3Nm

 62

2 6 8 13 Ft2
4 10
A B Ft8
Fr2 Fr8

24 47 5 47 29 48 28

W2+Fr2 W8+Fr8 W13

W4 W6
W10
(a) V.L.D
RA RB

Ft8
(b) H.L.D
Ft2 RB
RA

182.5 264
191
174

92
71
(c) V.B.M.D

685
(d) H.B.M.D
496
363

329
7.152 183

734
532
406

372
196
92.3
(e) C.B.M.D

Fig.4.8. Loading and Bending Moment Diagram of Counter Shaft

M 4 =√( M 4V )2 +( M 4H )2 =√ 174 2 +3292 =372Nm

M 6 =√( M 6V )2 +( M 6H )2= √182 .52 +3632 =406Nm
M 8 =√ ( M 8V )2 +( M 8H )2= √264 2 +6852 =734Nm
M 13=√( M 13V )2 +(M 13H )2 =√ 1912 +496 2 =532Nm
M 10=√( M 10V )2 +(M 10H )2 =√ 712 +1832 =196Nm
 63

M b( max )=734
Maximum bending moment, Nm
Maximum bending moment occurs at gear with keyway,
S s =0 . 18×Su ×0 . 75=0. 18×2170×0 . 75=293Mpa
S s =0 . 3×S y×0. 75=0 .3×1860×0.75=419 Mpa

Choose,
S s =293Mpa
For rotating shaft with load gradually applied,
K b =1 .5,Kt =1 , (From Table A-6)
d
k = =0. 25d
4 , L=370 mm
L
<115
Assume, k
1
α=
1−0 . 0044 ( Lk )
1 1 d
α= = =
1−0 . 0044 ( 4Ld ) 1−0 . 0044 ( 4×0d.370 ) d−6 .512×10−3

For solid shaft subjected to combine bending, torsion and axial load.
2
d 3
=
16
πS s √( αF d
Kb M b+ a
8 )
+( K t M t )2

2
7722d2

d
d3 =
16
π ×293×10
6

= 0.0274 m = 27.4 mm
√( 1. 5×734 + -3
8(d-6. 512×10 ) )
+(1×3 21)2

used d = 28 mm

4.3.3. Calculation of First Speed Position of Output Shaft

L= 510 mm
6150 OQ T400 heat-treated alloy steel material
S u =2170 Mpa, S y =1860 Mpa
Design power = 94 kW
 64

Shaft speed = 1167 rpm

D7 = 116 mm
Helix angle of D7, ψ = 30°

Pressure angle = 20°

W3 = 7.087 N
W5 = 17.81 N
W7 = 27.38 N
W9 = 5.716 N
W 11 = 21.625 N
For torsional moment of shaft, Mt
9550×kW 9550×94
Mt = = = 769 .24
rpm 1167 Nm
To find tangential force,
2Mt 2×769 . 24
F t7 = = = 13263
D7 116×10 -3 N
To find axial force and radial force,
Fa7 = F t tan ψ = 13263×tan30 = 7657 .4 N

tan φ N =tan φ×cosψ

φ N = tan -1 (tan20×cos30)
=17 .5 °
F r7 = F t tan φN =13263×tan17. 5

= 4182 N
For Vertical Moment,

Taking moment about A, ∑ MA ( +) = 0 (clockwise positive)

(W 3 ×0 . 034 )+(W 5 ×0 . 058)+((W 7 −F r7 )×0 .111 )+(W 11 ×0 .141 )

+(W 9 ×0 . 209)+(R B ×0 . 235 )=0
 65

(7.087×0 . 034 )+(17 . 81×0 . 058)+((27 .38−4182)×0 . 111)+(21 .625×0.141 )

+(5 .716×0 .209 )+0 .235R B=0

RB = 1939 N

∑ F y (+↑)=0
F r7−R A −R B −W 3 −W 5 −W 7 −W 11−W 9 =0
4182−R A −1939−7 . 087−17 . 81−27 . 38−21 . 625−5 . 716=0
R A =2163 N
For Horizontal Moment,

Taking moment about A, ∑ MA ( +) = 0 (clockwise positive)

( F t7×0 .111)−( RB ×0 .235 )= 0
(13263×0 . 111)−(0. 235R B )=0
RB = 6265 N

∑ F y (↑+)=0
R A +R B − F t7=0
R A = 13263−6265=6998 N
For Vertical Bending Moment,
M 3V =(−R A ×0 . 034 )=(−2163×0 . 034)=−74 Nm

M 5V = (−R A ×0 . 058)−(W 3 ×0 . 024 )

= (−2163×0 . 058 )−(7 . 087×0 .024 )=−125 Nm
M 7V =(−R A×0 . 111)−(W 3 ×0 .077 )−(W 5 ×0 . 053)
=(−2163×0 .111)−(7 . 087×0 . 077 )−(17 . 81×0. 053 )
=−242 Nm
M 11V=(−R A×0 . 141)−(W 3 ×0 . 107)−(W 5 ×0 . 083)−((W 7 −F r7 )×0. 03 )
=(−2163×0 .141)−(7 . 087×0. 107 )−(17 . 81×0. 083 )
−((27. 38−4182)×0 .03 )
=−183 Nm
M 9V =(−R A ×0. 209 )−(W 3×0. 175 )−(W 5×0. 151)−((W 7 −F r7 )×0 . 098 )
−(W 11 ×0 . 068)
=(−2163×0 .209)−(7 .087×0 . 175)−(17 . 81×0 .151 )
−((27 .38−4182 )×0 . 098)−(21. 625×0 .068 )
= −50 Nm
 66

For Horizontal Bending Moment,

M 3H =( R A×0 . 034 )=(6998×0 . 034 )=238 Nm
M 5H = ( R A ×0 . 058) = (6998×0 . 058)= 406 Nm

M 7H = ( R A ×0 .111 ) =(6998×0 . 111)=777 Nm

M 11H = (R A ×0. 141)−( F t ×0 .03 )

=(6998×0 .141 )−(13263×0 . 03)=589Nm
M 9H = ( R A ×0 .209 )−(F t ×0 . 098 )
= (6998×0 .209 )−(13263×0 . 098)=163Nm
 67

7
5 11 9
3
A B
Fr7
34 24 53 30 68 26
Ft7

W3 W5 W11
RA W7 W9 RB
(a) V.L.D
Fr7

Ft7

(b) H.L.D
RA RB

74 50
125
183
242 (c)V.B.M.D

777
589
406
238
163
(d) H.B.M.D

814
617
425

249
80
(e) C.B.M.D

Fig.4.9. Loading and Bending Moment Diagram of Output Shaft

From Vertical and Horizontal Moment,

M 3= √( M 3V )2 +( M 3H )2 =√ 742 +2382 =249Nm

M 5= √( M 5V )2 +( M 5H )2 =√ 1252 +4062 =425Nm

 68

M 7 =√( M 7V )2 +( M 7H )2 =√ 2422 +777 2=814Nm

M 11= √( M 11V )2 +( M 11H )2 =√183 2 +5892 =617 Nm

M 9 =√( M 9V )2 +( M 9H )2 =√50 2 +632 =80 Nm

M b( max )=814
Maximum bending moment, Nm
Maximum bending moment occurs at gear with keyway,
S s =0 . 3S y ×0.75=0 .3×1860×0. 75=419 Mpa
S s =0 . 18Su ×0. 75=0. 18×2170×0 . 75=293 Mpa

Choose,
S s =293Mpa

For rotating shaft with load gradually applied,

K b =1 .5,Kt =1 (From Table A-6)

d
k = =0. 25d
4
L=510 mm
L
<115
Assume, k
1
α=
1−0 . 0044 ( Lk )
1 1
α= =
1−0 . 0044 ( 4Ld ) 1−0 . 0044 ( 4×0d.510 )
d
= d−8 . 976×10−3
For solid shaft subjected to combine bending, torsion and axial load.
2
αF a d
3
d =
16
πS s √( K b M b+
8 )
+( K t M t )2

2
7657 . 4d 2
d3 =
16
π ×293×10
6

d = 0.0295m = 29.5mm
√( 1. 5×814+ -3
8(d-8. 976×10 ) ) +(1×769. 24 )2
 69

used d = 31 mm
4.3.4. Design Calculation of Idler Shaft
AISI 6150 steel is used the shaft.
Ultimate stress, Su = 2170 Mpa
Yield Stress, Sy = 1860 Mpa
W = 129kg×9.81 = 1265.5N

∑ Fy(↑+)=0
RB −W=0
RB =1265. 5N
Span AB (0<x< 152mm)
X

(-)

F xx=−W (constant )
M xx=−Wx
x=0,M A=0

x=L,M B =−WL=−1265 . 5×152×10−3 =−192. 4Nm

Maximum bending moment = − 192.4Nm
Maximum bending moment occurs at gear without keyway.
S s =0 . 3S y =0 .3×1860=558 Mpa
S s =0 . 18Su =0. 18×2170=390 . 6Mpa

Choose,
S s =391Mpa
Torsional Moment is zero because of the cantilever beam.
For stationary shaft with load suddenly applied,
K b =2,K t =1 . 5 (From Table A-6)
16
d 3= 6√
( K b M b )2 +( K t M t )2
π ×391×10
16
d3 = 6√
(2×192. 4 )2 +(1 .5×0 )2
π ×391×10
 70

d = 0.017 m = 17mm
used d = 18 mm
X
W
152

B
A

x
RB
X

(a) S.F.D

_
(b) B.M.D

Fig.4.10. Loading and Bending Moment Diagram of Idler Shaft. (a) Shearing Force
Diagram. (b) Bending Moment Diagram

4.3.5. Results Data of Shafts

The result data of shaft design calculation and existing design are
comparatively shown in Table 4.4.
Table 4.4. Comparison of Shafts
Results of Design
Existing Design
Calculation
Details
Diameter Length Diameter Length
(mm) (mm) (mm) (mm)

Input Shaft 20 218 21 218

Counter Shaft 28 370 30 370

Output Shaft 31 510 31 510

 71

Idler Shaft 18 152 19 152

4.4. Bearing Selection

In bearing selection, firstly, choose bearing life of machine 12,000 working
hours from Table A-8. Bearing selections of input, output and counter shafts are
described as follows.

4.4.1. Bearing Selection for Input Shaft

Single roll deep groove ball bearings are chosen for left and right bearing on
the input shaft.
For left bearing selection
W A =3873 N

W R =√ 8692 +29812 = 3105 N

Shaft speed = 4200 rpm
Lh =12000hr (From Table A-8)

Bearing in revolution,
L=60N× Lh=60×4200×12000=3024×106 rev
Basic dynamic equivalent radial load,
W =XVW R+YW A
W A 3873
= =1. 25>e
W R 3105 (From Table A-7)
X = 0.56, Y=1, V=1, for inner ring rotation
W =(0 . 56×1×3105)+(1×3873)=5612 N
Uniform and steady load, Ks =1 (From Table A-9)
W = 5612 N
Dynamic load rating,
k = 1, for ball bearing

C=W( L/106 )1/ k =5612×((3024×106 )/10 6 )1/3 =81 kN

Select bearing No.314.
C o =63 kN , C = 81.5 kN
 72

W A 3873
= =0 .06
C O 63000
X =0.56, Y=1.67

W =XVW R+YW A
W =(0 . 56×1×3105)+(1 . 67×3873 )=8207 N
6 1/ k 6 6 1/3
C =W( L/10 ) =8207×((3024×10 )/10 ) =119 kN
From Table A-10, bearing No.319 which has C 120 kN is selected.

For right bearing selection

W A =3873 N

W R =√ 12232 +3727 2= 3923 N

Shaft speed= 4200 rpm
Lh =12000hr (From Table A-8)

Bearing in revolution,
L=60N× Lh=60×4200×12000=3024×106 rev
Basic dynamic equivalent radial load,
W =XVW R +YW A
W A 3873
= =0 .99> e
W R 3923 (From Table A-7)
X = 0.56, Y=1, V=1, for inner ring rotation
W =(0 . 56×1×3923)+(1×3873)=6069. 9 N
Uniform and steady load, Ks =1 (From Table A-9)
W = 6069.9 N
Dynamic load rating,
k = 1, for ball bearing
6 1/ k 6 6 1/3
C =W( L/10 ) = 6069 . 9×((3024×10 )/10 ) =88 kN
Select bearing No.315.
C o =72 kN , C=90 kN
W A 3873
= = 0 . 054
C o 72000
X = 0.56, Y= 1.71
 73

W =XVW R +YW A
W =(0 . 56×1×3923)+(1 . 71×3873)= 8819. 7 N
C =W( L/106 )1/ k =8819 .7×((3024×106 )/10 6 )1/3 =128 kN
From Table A-10, bearing No.320 which has have C 137 kN is selected.
4.4.2. Bearing Selection for Counter Shaft
Taper roller bearings are chosen for left and right bearing on the counter shaft.
For left bearing selection
W A =7722N

W R=√ 38212 +2982 =3836 N

Shaft speed= 2800 rpm
Lh =12000hr (From Table A-8)

Bearing in revolution,
L=60N× Lh=60×2800×12000=2016×106 rev
Basic dynamic equivalent radial load,
W =XVW R+YW A
W A 7722
= =2. 01>e
W R 3836 (From Table A-7)
X = 0.4, Y=1.6, V=1, for inner ring rotation
W =(0 . 4×1×3836 )+(1 . 6×7722 )=13889 .6 N
Uniform and steady load, Ks =1 (From Table A-9)
W =13889.6 N
Dynamic load rating,
k = 10/3, for roller bearing.
6 1/ k 6 6 3/10
C =W( L/10 ) =13889 .6×((2016×10 )/10 ) =136 kN
From Table A-12, bearing No. HR 32309 J with C = 144 kN is selected.

For right bearing selection

W A =7722 N

W R=√ 2519. 52 +65262 = 6995. 5 N

Shaft speed=2800 rpm
 74

Lh =12000hr (From Table A-8)

Bearing in revolution,
L =60N×Lh =60×2800×12000=2016×10 6 rev
Basic dynamic equivalent radial load,
W =XVW R+YW A
W A 7722
= =1 .1>e
W R 6995 .5 (From Table A-7)
X = 0.4, Y=1.6, V=1, for inner ring rotation
W =(0 . 4×1×6995 . 5)+(1. 6×7722)= 14381 N
Uniform and steady load, Ks =1 (From Table A-9)
W = 14381 N
Dynamic load rating,
k = 10/3, for roller bearing.
6 1/ k 6 6 3/10
C=W( L/10 ) =14381×((2016×10 )/10 ) =141 kN
From Table A-12, bearing No. HR 32309J with C = 144 kN is selected.

4.4.3. Bearing Selection for Output Shaft

Single roll deep groove ball bearings are chosen for left and right bearing on
the output shaft.
For left bearing selection
W A =7657 . 4N

W R =√ 21632 +6998 2= 7325 N

Shaft speed= 1167 rpm
Lh =12000hr (From Table A-8)

Bearing in revolution,
L=60N× Lh=60×1167×12000=840×10 6 rev
Basic dynamic equivalent radial load,
W =XVW R +YW A
W A 7657 . 4
= =1 .05> e
W R 7325 (From Table A-7)
X = 0.56, Y=1, V=1
 75

W =(0 . 56×1×7325)+(1×7657 . 4 )=11759 N

Uniform and steady load, Ks =1 (From Table A-9)
W = 11759 N
Dynamic load rating,
k = 1, for ball bearing
6 1/ k 6 6 1/3
C =W( L/10 ) =11759×((840×10 )/10 ) =111 kN
Select bearing No.318.
C o =98 kN , C =112 kN
W A 7657 . 4
= =0 . 08
C o 98000
X = 0.56, Y=1.57
W =XVW R+YW A
W=(0 .56×1×7325 )+(1 .57×7657 . 4 )=16124 N
6 1/ k 6 6 1/3
C =W( L/10 ) =16124×((840×10 )/10 ) =152 kN
From Table A-10, bearing No.322 which has C 160 kN is selected.

For right bearing selection

W A =7657 . 4 N

W R =√ 19392 +6265 2=6558 N

Shaft speed= 1167 rpm
Lh =12000hr (From Table A-8)

Bearing in revolution,
L=60N× Lh=60×1167×12000=840×10 6 rev
Basic dynamic equivalent radial load,
W=XVW R + YW A
W A 7657 . 4
= =1 .17>e
W R 6558 (From Table A-7)
X=0.56, Y=1, V=1
W=(0 .56×1×6558)+(1×7657 . 4 )=11329. 9 N
Uniform and steady load, Ks =1 (From Table A-9)
W= 11329.9 N
Dynamic load rating,
 76

k = 1, for ball bearing

6 1/ k 6 6 1/3
C=W( L/10 ) =11329. 9×((840×10 )/10 ) =107 kN
Select bearing No.318.
C o =98 kN, C= 112 kN
W A 7657 . 4
= =0 . 08
C o 98000
X=0.56, Y=1.57
W=XVW R + YW A
W=(0 .56×1×6558)+(1 .57×7657 . 4 )=15695 N
6 1/ k 6 6 1/3
C=W( L/10 ) =15695×((840×10 )/10 ) =148 kN
From Table A-10, bearing No.322 which has C 160kN is selected.

Table 4.5. Results of Bearing Selection

Type of Shaft Bearing No. (L/R) Type of Bearing
Input Shaft 319/320 Single row deep groove ball bearing
Counter Shaft HR 32309J/HR 32309J Taper roller bearing
Output Shaft 322/322 Single row deep groove ball bearing