Unit V
Gear Box
Machine tools like lathe, milling machines, etc., require a wide range of spindle speeds.
Because a machine tool is adoptable for cutting different types of meals having different
properties using varying grades of cutting tools on work-pieces of different diameters.
Thus the provision of variable spindle speeds is necessary in order to meet different
requirements. The various methods used for obtaining different speeds of machine tool spindle
are as follows:
i. By using a gear box mechanism,
ii. By using a cone pulley arrangement,
iii. By using a variable speed electric motor, and
iv. By hydraulic operation.
Among these methods, the gear box method is very popularly used. In this chapter, we shall
discuss the design of gear boxes, in detail, in the following sections.
REQUIREMENTS OF A SPEED GEAR BOXES
A speed gear box should have the following requirements:
It should provide the designed series of spindle speeds.
It should transmit the required amount of power to the spindle.
It should provide smooth silent operation of the transmission.
It should have simple construction.
Mechanism of speed gear boxes should be easily accessible so that it is easier to carry out
preventive maintenance.
THE SPEEDS IN MACHINE TOOL GEAR BOXES ARE IN GEOMETRIC
PROGRESSION. WHY?
The speeds in gear boxes can be arranged in arithmetic progression (A.P.), geometric
progression (G.P.), harmonic progression (H.P.), and logarithmic progression (L.P.). However,
when the speeds are arranged in G.P., it has the following advantages over the other
progressions.
1. The speed loss in minimum.
i.e., Speed loss = Desired optimum speed Available speed
2. The number of gears to be employed is minimum.
3. G.P. provides a more even range of spindle speeds at each step.
4. The layout is comparatively very compact.
5. Productivity of a machining operation, i.e., surface area of the metal removed in unit
time, is constant in the whole speed range.
6. G.P. machine tool spindle speeds can be selected easily from preferred numbers. Because
preferred numbers are in geometric progression.
METHODS FOR CHANGING SPEED IN GEAR BOXES
The two important methods widely used are:
1. Sliding mesh gear box, and
2. Constant mesh gear box.
Sliding Mesh Gear Box
It is the oldest and simplest from of gear box. Sliding type gear boxes are quite
commonly used in general purpose machine tools. In order to mesh gears on the main shaft with
appropriate gears on the spindle shaft for obtaining different speeds, they are moved to the right
or the left. It derives its name from the fact that the meshing of the gears takes place by sliding of
gears on each other.
Constant Mesh Gear Box
It derives its name from the fact that all the gears whether of the countershaft or the main
shaft are in constant mesh with each other. It is also known as a silent or quite gear box. It gives
a quieter operation and makes gear changing easier by employing helical gears for the constant
mesh. In order to connect the required gear wheel by means of teeth on the side of the gear
wheel, a separate sliding member is employed.
PREFERRED NUMBERS
Preferred numbers are the conventionally rounded off values derived from geometric
series. There are five basic series, denoted as R 5, R 10, R 20, R 40 and R 80 series. The symbol
‘R’ is used as a tribute to French engineer Charles Renard, who introduced the preferred numbers
first. Preferred numbers assist the designer in avoiding the selection of sizes in an arbitrary
manner.
Step ratio or series ratio or progression Ratio
When the spindle speeds are arranged in geometric progression, then the ratio between
the two adjacent speeds is known as step ratio or progression ratio. It denoted by ϕ.
N 3 N3
= =ϕ
N1 N2
Structural formula:
N= number of speeds available at the spindle.
P1, P2….= stage numbers in the gear box, and
X1,X2….= Characteristic of stage.
The structural formula is given as
n= P1(X1). P2(X2). P3(X3)
X1= 1, X2= P1, X3= P1.P2, X3= P1.P2.P3
GEAR BOX HOUSING
The gearbox housing is a member of the gearbox but it is a non-rotating member. It lies at
the center of the gearbox and joins all other elements of the gearbox like flanges, bearings and
spiral bevel gears. The base to adjust the gears with a certain tooth bearing and backlash are the
angle of the housing and the offshoot of the holes. This ensures the best possible running of the
gears and standard attribute of transmission.
Gearbox Housings as Cast
Gearbox housings as cast, which are also known as cast gearbox housings are the gear
housings that are made by a process called metal-casting. In other words, we can say that the cast
gearbox housings are made by using molds. These types of gearbox housings are very sturdy and
durable in nature. These housings are available in various types of seals like lip seal, double lip
seal, taconite seal, etc.
Gearbox Housings as Fabricated
The fabricated gearbox housings are manufactured by using various industrial standard
materials like cast iron, modular cast iron, steel, and so. Irrespective of the cast gearbox
housings, these gearbox housings are fabricated in hi-tech machining centers. These housings are
ideal for heavy industrial gears.
Working and Utility of Gearbox Housing
An oil outlet opening is present in the Gearbox Housing. A gearbox Housing also
consists a method which assists it to work upon the fluid level of the gearbox. The gearbox
housing contains such a device which can work from two different positions.
In the first working position, the height of the fluid level with in the gearbox housing is
predetermined during its filling and operation. This predetermination is done by an upper
opening of the device. In the second working position, primarily the provision is made to drain-
out the gearbox oil.
For this purpose, an oil drain opening of the device is released. This draining opening is
adjusted properly beneath the upper opening. This adjustment allows to drain-out a major portion
of oil disposed in the gearbox. The device which is used to open the drain opening is used from
outside of the gear box housing.
Structure of Gearbox Housing
The material that is used most commonly to manufacture gearbox housing is nylon.
Through the gear housing surfaces and thermal condition of the surrounding air, most of the heat
is dispelled by the process of radiation. Dispelling of heat through heat radiation depends on
some other factors also, and these factors are: surrounding structure within the gearbox and the
various components which are present.
In a gearing housing, there is a bearing pocket. An extra bearing is installed at the center
of the bearing pocket. This ensures the permanent seal and proper alignment of the bearing.
Applications of Gearbox Housing
Gear housing has a lot of different applications. Some of these applications are:
In aerospace transmission.
In motor sport transmission.
In other different kinds of transmission.
In transmission of heat in robots, electric motors, solar gas turbine motors.
It forms a complete wet oil slum in the engines. This helps the engine to drive out the
residues from inside.
