Discussion Group: H

ME3200 Machine Design Project

Semester 5

Detailed Design Calculation

By

Index No. Name Marks

180341U YHCB Kumarasiri

Date of submission 09/12/2021

Due date of submission 09/12/2021

Discussion group advisors’ names and affiliations

Department of Mechanical Engineering,

Dr TP Miyanwala
University of Moratuwa
Dr ABDS Department of Mechanical Engineering,
Priyadarshana University of Moratuwa

Department of Mechanical Engineering

University of Moratuwa
Sri Lanka
1 Introduction
The report is about a design of marine gear box for tugboat which is operating on
escort purposes. The gear box consists with 3 forward gear and a reverse gear mechanism
which let all the 3 forward gears operating too backward. Present tugboats are using
Thrusters that let the propeller axis to turn 3600. And the tugboat isn’t using several gears to
operate thus, one forward gear can maintain all the requirement under its speed range.

The propeller is the main component that should consider applying the engine power
efficiently. To select a suitable propeller, it has a particular method of comparing the vessel’s
engine power curve and the propeller curve of the relevant propeller in order to minimize the
energy wastage and acquire the full acceleration to the vessel under the engine capability. So,
the selected propeller has ability acquire any torque and rpm in range of the engine provide.

Therefore, it is unnecessary to include several gears to the gearbox. If it applied, then

the used propeller should be a variable pitch propeller in order to minimize the power
wastage when changing the gear. But there is an advantage of applying several forward gears
to the gearbox that, it enables to drive vessel safely as it is reducing the propeller rpm when
the maximum power is applied.

2 Gear calculations

G H
Reverse Forward
gear gear

I
Input shaft

Figure 01: Gear layout – Front elevation

1
 E G, H
A C

Output shaft
Input shaft

Lay shaft
D F I
B

Figure 02: Gear layout – Side elevation

2.1 Gear selection – Theory

2.1.1 Parameters
There are several parameters that used to design a gear for a particular purpose.

Parameter Notation

Power transmitted P

Gear ratio V.R.

Distance between shafts. L

Service factor Cs

Pinion’s rpm Np

Pressure angle φ

Ultimate tensile strength of the selected

σu
material

Elastic modulus of the selected material E

Brinell hardness number of the selected

B.H.N.
material

Table 01: Parameters use for calculation on gears

2
2.1.2 Procedure that followed when design a gear
It needs to find the gear and the pinion diameter. It can be done using following equations.[1]

𝐷𝑝 𝐷𝐺
𝐿= + ……………………. (1)
2 2

𝐷𝐺
𝑉. 𝑅. = ……………………. (2)
𝐷𝑝

Then it needs to find the Pitch line velocity.[1]

𝜋. 𝐷𝑝. 𝑁𝑝
𝑉= ……………………. (3)
60 × 1000

Next step is to determine the velocity factor. To determine the velocity factor, it shout
consider the pitch line velocity and what type of gear cut going to be used. [1],[2]

3
𝐶𝑣 = 3+𝑣; V ≤ 12.5 m s-1, Ordinary cut gears ………………. (4)

4.5
𝐶𝑣 = 4.5+𝑣; V ≤ 12.5 m s-1, Carefully cut gears ……………… (5)

6
𝐶𝑣 = 6+𝑣; V ≤ 20 m s-1, Very accurately cut gears …………… (6)

0.75
𝐶𝑣 = 0.75+ 𝑣; V ≤ 20 m s-1, Precision cut gears ………………. (7)
√

5.56
𝐶𝑣 = 5.56+ 𝑣; V ≥ 20 m s-1, Precision cut gears ………………. (8)
√

Then, it needs to select the suitable equation to calculate the tooth form factor, 𝑦𝑝 by using
pressure angle that have chosen.[1]

for 14 1 /2° composite and full depth involute system,

0.684
𝑦𝑝 = 0.124 − ……………………. (9)
𝑇𝑝

for 20° full depth involute system,

0.912
𝑦𝑝 = 0.154 − ……………………. (10)
𝑇𝑝

3
for 20° stub system,

0.841
𝑦𝑝 = 0.175 − ……………………. (11)
𝑇𝑝

Where; 𝑇𝑝 is number of teeth in the pinion,

𝐷𝑃
𝑇𝑃 = ……………………. (12)
𝑚

Number of teeth in the gear can be calculated as,

𝐷𝐺
𝑇𝐺 = ……………………. (13)
𝑚

Here, m is the module of the gear

By combination of the Equations 12 and 13, 𝑦𝑝 can be obtain using the pinion
diameter and the gear module as a function of the gear module.

The next step is to find the tangential tooth load by using the given equation below.[1]

𝑃
𝑊𝑇 = × 𝐶𝑣 ……………………. (14)
𝑉

Service factor (𝐶𝑣 ) determine by the data acquired by the following table.

Table 02: Service factor

Lewise equation is used to derive the tangential tooth load (𝑊𝑇 ) as function of gear module.
[1]

𝑊𝑇 = 𝜎𝑤 𝑏𝑚𝜋𝑦𝑝 ……………………. (15)

Where;

4
 𝜎𝑤 = 𝐶𝑣 𝜎0 …………………… (16) and
𝜎0 = Allowable static stress is given by
𝜎𝑢
𝜎0 = ……………………. (17)
3
The ultimate tensile strength and the B.H.N are dependent on the material that used to
manufacture the gear.
Face width; 𝑏 = 𝑘𝑚 …………… (18); 𝑘 ∈ (10,12.5)

From the equations, (15), (16) and (18), it can be deriving a polynomial equation of
gear module with degree of 3. By solving the equation, gear module can be obtained to the
relevant gear. The suitable module number can be acquired using following table.

Table 03: Standard values for module

Final step is to check the design gear load can withstand for the wear tooth load and the
endurance strength of the tooth by comparing with its dynamic load.

Dynamic load can be determine using the following equation.[1]

……………………. (19)
5
 21𝑉(𝑏𝐶 + 𝑊𝑇 )
𝑊𝐷 = 𝑊𝑇 +
21𝑉 + √𝑏𝐶 + 𝑊𝑇
Where; C = deformation factor
𝑘ⅇ
𝐶=
1 1 ……………………. (20)
+
𝐸𝑃 𝐸𝐺

If 𝐸𝑃 = 𝐸𝐺 = 𝐸 (Gear and pinion are made out of the same material), then;
𝑘ⅇ𝐸
𝑐= ……………………. (21)
2
Here, k: factor depending upon the form of the teeth: -
= 0.107, for 14 1/ 2 ° full depth involute system.
= 0.111, for 20° full depth involute system.
= 0.115 for 20° stub system.
e: Tooth error action in mm.

Tooth error can be calculated using the following table. [1]

Table 04: Tooth error in action according to the gear module

wear tooth load can be determine using following equation[1],

𝑊𝑤 = 𝐷𝑝 ⋅ 𝑏 ⋅ 𝑄 ⋅ 𝐾 ……………………. (22)
6
Where; Q = Ratio factor

2×𝑉𝑅
𝑄 = 𝑉𝑅+1 ; for external gears, …………………. (23)

2×𝑉𝑅
𝑄 = 𝑉𝑅−1 ; for internal gears …………………... (24) and

K = Load-stress factor (also known as material combination factor) in N/mm2

𝜎𝑒𝑠 2 𝑎𝑠𝑖𝑛 𝜙 1 1
𝐾= [ + ] ……………………. (25)
1⋅4 𝐸𝑃 𝐸𝐺
If 𝐸𝑃 = 𝐸𝐺 = 𝐸 (Gear and pinion are made out of the same material), then;

𝜎𝑒𝑠 2 𝑎𝑠𝑖𝑛 𝜙 2 ……………………. (26)

𝐾= [ ]
1⋅4 𝐸
Here surface endurance limit (𝜎𝑒𝑠 ) can be calculated by using following equation.

𝜎𝑒𝑠 = 2.8 × 𝐵. 𝐻. 𝑁. −70 …………………. (27)

wear tooth load can be determine using following equation[1],

𝑊𝑠 = 𝜎𝑒 ⋅ 𝑏 ⋅ 𝜋 ⋅ 𝑚 ⋅ 𝑦𝑝 ……………………. (28)

If 𝑊𝐷 < 𝑊𝑠 , 𝑊𝑤 condition is satisfied by the design, then the design gear is suitable for the
particular operation.

Here flexural endurance limit (𝜎𝑒 ) can be calculated by using following equation.

𝜎𝑒 = 1.75 × 𝐵. 𝐻. 𝑁. ……………………. (29)

2.2 Gear selection – Calculations

2.2.1 Material selection.

Material that used to manufacture the gear is done lastly by considering the cost and
the ultimate tensile strength and B.H.N. required in order to withstand to the power
transmitted. By considering those factors, case hardened steel 0.5% Nickel (BHN = 600 case)
is the most suitable material that can be used to manufacture all the gear sets. ([1, p.
1056], Table 28.3)

7
2.2.2 1st gear (E, F – figure 02)

Parameter Value

Power transmitted – P 749 kW

Gear ratio – V.R. 3.14

Distance between shafts – L 500 mm

Service factor – Cs 1.25 (light shock, 8 – 10 hours per day)

Pinion’s rpm – Np 1500 rpm

Pressure angle – φ 14 1/20 (Full depth involute system)

Ultimate tensile strength of the selected

866 N/mm2
material – σu

Elastic modulus of the selected material – E 190000 N/mm2

Brinell hardness number of the selected

600
material – B.H.N.

surface endurance limit (𝜎𝑒𝑠 ) 1610 N/mm2 (Equation 27)

flexural endurance limit (𝜎𝑒 ) 1050 N/mm2 (Equation 28)

Teeth form factor (k) 0.107 (for 14 1/ 2 ° full depth involute

system)

Deformation factor (C) 335.45 N/mm (Equation 20)

Ratio factor (Q) 1.5169 (Equation 23 – External gears)

Load stress factor (K) 4.8798 N/mm2 (Equation (26))

Face width (b) 12m (m = Gear module)

Table 05: Parameters use on calculation of 1st gear

Pinion diameter – Dp = 241.55 mm (Equation (1) and (2))

Gear diameter – DG = 758.45 mm (Equation (2))

8
Pitch line velocity – V = 18.97 m s-1 (Equation (3))

Velocity Factor – Cv = 0.1469 (V ≤ 20 m/s – precision cut gears, Equation (7))

Tooth form factor of the pinion –

𝑦𝑝 = 0.124 − 0.00283𝑚
(for 14 1/2° composite and full depth involute system, Equations (9), (12))

Tangential tooth load - Wt = 49351.72 N (Equation (14))

By Lewies equation - 4.527𝑚3 − 198.229𝑚2 + 49351.7 = 0 (Equations (15), (17), (18))

Then, gear module – m = 22 mm (Table 03)

By considering the gear module, it can be calculated;

Face width – b = 264 mm

Number of teeth in the pinion – TP = 11

Number of teeth in the gear – TG = 34

Tooth form factor – yp = 0.0617

Tooth error in action – e = 0.033

Checking the gear for Dynamic, Endurance strength and wear loads.

Dynamic load – WD = 120728 N (Equation (19))

Endurance strength of a tooth – WS = 1182116 N (Equation (28))

Maximum limiting load for wear – WW = 472022 N (Equation (22))

Calculation gives that WD < WS, WW. So, the design is safe for the operation.

2.2.3 2nd gear (C, D – figure 02)

Parameter Value

Power transmitted – P 749 kW

Gear ratio – V.R. 1.66

9
Distance between shafts – L 500 mm

Service factor – Cs 1.25 (light shock, 8 – 10 hours per day)

Pinion’s rpm – Np 1500 rpm

Pressure angle – φ 14 1/20 (Full depth involute system)

Ultimate tensile strength of the selected

866 N/mm2
material – σu

Elastic modulus of the selected material – E 190000 N/mm2

Brinell hardness number of the selected

600
material – B.H.N.

surface endurance limit (𝜎𝑒𝑠 ) 1610 N/mm2 (Equation 27)

flexural endurance limit (𝜎𝑒 ) 1050 N/mm2 (Equation 28)

Teeth form factor (k) 0.107 (for 14 1/ 2 ° full depth involute

system)

Deformation factor (C) 189.069 N/mm (Equation 20)

Ratio factor (Q) 1.24812 (Equation 23 – External gears)

Load stress factor (K) 4.8798 N/mm2 (Equation (26))

Face width (b) 12m (m = Gear module)

Table 05: Parameters use on calculation of 1st gear

Pinion diameter – Dp = 375.94 mm (Equation (1) and (2))

Gear diameter – DG = 624.06 mm (Equation (2))

Pitch line velocity – V = 29.53 m s-1 (Equation (3))

Velocity Factor – Cv = 0.5057 (V ≥ 20 m/s – precision cut gears, Equation (8))

Tooth form factor of the pinion –

𝑦𝑝 = 0.124 − 0.00182𝑚
10
 (for 14 1/2° composite and full depth involute system, Equations (9), (12))

Tangential tooth load - Wt = 31709.1 N (Equation (14))

By Lewies equation - 10.0136𝑚3 − 682.458𝑚2 + 31709.1 = 0 (Equations (15), (17), (18))

Then, gear module – m = 7 mm (Table 03)

By considering the gear module, it can be calculated;

Face width – b = 84 mm

Number of teeth in the pinion – TP = 54

Number of teeth in the gear – TG = 89

Tooth form factor – yp = 0.1113

Tooth error in action – e = 0.0186

Checking the gear for Dynamic, Endurance strength and wear loads.

Dynamic load – WD = 66913.8 N (Equation (19))

Endurance strength of a tooth – WS = 215810 N (Equation (28))

Maximum limiting load for wear – WW = 192333 N (Equation (22))

Calculation gives that WD < WS, WW. So, the design is safe for the operation.

2.2.4 3rd gear (A, B – figure 02)

Parameter Value

Power transmitted – P 749 kW

Gear ratio – V.R. 1.02

Distance between shafts – L 500 mm

Service factor – Cs 1.25 (light shock, 8 – 10 hours per day)

Pinion’s rpm – Np 1500 rpm

11
Pressure angle – φ 14 1/20 (Full depth involute system)

Ultimate tensile strength of the selected

866 N/mm2
material – σu

Elastic modulus of the selected material – E 190000 N/mm2

Brinell hardness number of the selected

600
material – B.H.N.

surface endurance limit (𝜎𝑒𝑠 ) 1610 N/mm2 (Equation 27)

flexural endurance limit (𝜎𝑒 ) 1050 N/mm2 (Equation 28)

Teeth form factor (k) 0.107 (for 14 1/ 2 ° full depth involute

system)

Deformation factor (C) 172.805 N/mm (Equation 20)

Ratio factor (Q) 1.0099 (Equation 23 – External gears)

Load stress factor (K) 4.8798 N/mm2 (Equation (26))

Face width (b) 12m (m = Gear module)

Table 05: Parameters use on calculation of 1st gear

Pinion diameter – Dp = 495.05 mm (Equation (1) and (2))

Gear diameter – DG = 504.95 mm (Equation (2))

Pitch line velocity – V = 38.88 m s-1 (Equation (3))

Velocity Factor – Cv = 0.5057 (V ≥ 20 m/s – precision cut gears, Equation (8))

Tooth form factor of the pinion –

𝑦𝑝 = 0.124 − 0.00138𝑚
(for 14 1/2° composite and full depth involute system, Equations (9), (12))

Tangential tooth load - Wt = 24079.8 N (Equation (14))

By Lewies equation - 7.0875𝑚3 − 636.076𝑚2 + 24079 = 0 (Equations (15), (17), (18))

12
Then, gear module – m = 6 mm (Table 03)

By considering the gear module, it can be calculated;

Face width – b = 72 mm

Number of teeth in the pinion – TP = 83

Number of teeth in the gear – TG = 84

Tooth form factor – yp = 0.11571

Tooth error in action – e = 0.017

Checking the gear for Dynamic, Endurance strength and wear loads.

Dynamic load – WD = 53674.8 N (Equation (19))

Endurance strength of a tooth – WS = 164890 N (Equation (28))

Maximum limiting load for wear – WW = 175655 N (Equation (22))

Calculation gives that WD < WS, WW. So, the design is safe for the operation.

2.2.5 Reverse and forward gear (G, H – figure 02)

Parameter Value

Power transmitted – P 749 kW

Gear ratio – V.R. 1

Distance between shafts – L 500 mm

Service factor – Cs 1.25 (light shock, 8 – 10 hours per day)

Pinion’s rpm – Np 1500 rpm

Pressure angle – φ 14 1/20 (Full depth involute system)

Ultimate tensile strength of the selected

866 N/mm2
material – σu

Elastic modulus of the selected material – E 190000 N/mm2

13
Brinell hardness number of the selected
600
material – B.H.N.

surface endurance limit (𝜎𝑒𝑠 ) 1610 N/mm2 (Equation 27)

flexural endurance limit (𝜎𝑒 ) 1050 N/mm2 (Equation 28)

Teeth form factor (k) 0.107 (for 14 1/ 2 ° full depth involute

system)

Deformation factor (C) 172.805 N/mm (Equation 20)

Ratio factor (Q) 1 (Equation 23 – External gears)

Load stress factor (K) 4.8798 N/mm2 (Equation (26))

Face width (b) 12m (m = Gear module)

Table 05: Parameters use on calculation of 1st gear

Pinion diameter – Dp = 500 mm (Equation (1) and (2))

Gear diameter – DG = 500 mm (Equation (2))

Pitch line velocity – V = 39.27 m s-1 (Equation (3))

Velocity Factor – Cv = 0.4701 (V ≥ 20 m/s – precision cut gears, Equation (8))

Tooth form factor of the pinion –

𝑦𝑝 = 0.124 − 0.00137𝑚
(for 14 1/2° composite and full depth involute system, Equations (9), (12))

Tangential tooth load - Wt = 23841.4 N (Equation (14))

By Lewies equation - 6.9989𝑚3 − 634.403𝑚2 + 23841.4 = 0 (Equations (15), (17), (18))

Then, gear module – m = 6 mm (Table 03)

By considering the gear module, it can be calculated;

Face width – b = 72 mm

Number of teeth in the pinion – TP = 83

14
Number of teeth in the gear – TG = 83

Tooth form factor – yp = 0.11579

Tooth error in action – e = 0.017

Checking the gear for Dynamic, Endurance strength and wear loads.

Dynamic load – WD = 53316.6 N (Equation (19))

Endurance strength of a tooth – WS = 165007 N (Equation (28))

Maximum limiting load for wear – WW = 175672 N (Equation (22))

Calculation gives that WD < WS, WW. So, the design is safe for the operation.

2.2.6 Gear I (figure 02)

Parameter Value

Power transmitted – P 749 kW

Gear ratio – V.R. 1

Distance between shafts – L 400 mm

Service factor – Cs 1.25 (light shock, 8 – 10 hours per day)

Pinion’s rpm – Np 1500 rpm

Pressure angle – φ 200 (Full depth involute system)

Ultimate tensile strength of the selected

866 N/mm2
material – σu

Elastic modulus of the selected material – E 190000 N/mm2

Brinell hardness number of the selected

600
material – B.H.N.

surface endurance limit (𝜎𝑒𝑠 ) 1610 N/mm2 (Equation 27)

flexural endurance limit (𝜎𝑒 ) 1050 N/mm2 (Equation 28)

15
Teeth form factor (k) 0.111 (for 20° full depth involute system)

Deformation factor (C) 179.265 N/mm (Equation 20)

Ratio factor (Q) 1 (Equation 23 – External gears)

Load stress factor (K) 6.6658 N/mm2 (Equation (26))

Face width (b) 12m (m = Gear module)

Table 05: Parameters use on calculation of 1st gear

Pinion diameter – Dp = 400 mm (Equation (1) and (2))

Gear diameter – DG = 400 mm (Equation (2))

Pitch line velocity – V = 31.42 m s-1 (Equation (3))

Velocity Factor – Cv = 0.4980 (V ≥ 20 m/s – precision cut gears, Equation (8))

Tooth form factor of the pinion –

𝑦𝑝 = 0.154 − 0.00228𝑚
(for 14 1/2° composite and full depth involute system, Equations (9), (12))

Tangential tooth load - Wt = 29801.8 N (Equation (14))

By Lewies equation - 12.356𝑚3 − 834.574𝑚2 + 29801.8 = 0 (Equations (15), (17), (18))

Then, gear module – m = 6 mm (Table 03)

By considering the gear module, it can be calculated;

Face width – b = 72 mm

Number of teeth in the pinion – TP = 67

Number of teeth in the gear – TG = 67

Tooth form factor – yp = 0.14032

Tooth error in action – e = 0.017

Checking the gear for Dynamic, Endurance strength and wear loads.

16
Dynamic load – WD = 62323.3 N (Equation (19))

Endurance strength of a tooth – WS = 199960 N (Equation (28))

Maximum limiting load for wear – WW = 191975 N (Equation (22))

Calculation gives that WD < WS, WW. So, the design is safe for the operation.

3 Shaft selection
G, H

Output shaft
C Input shaft
A E

Lay shaft
B D F I
324 mm
144 mm

84 mm

100 mm
200 mm
182 mm

72 mm
264 mm

50 mm
72 mm

72 mm

Figure 3: Gear layout – Side elevation

3.1 Lay shaft calculation

Calculations will be done assuming weight of shaft and gears are negligible. The 1st
gear stage is taken for this calculation. Because there is maximum tangential load and
maximum torque.

17
 Figure 4: Forces on lay shaft

Here F, R is tangential and radial load respectively. All data taken from gear selection
calculations.

𝐹𝐼 = 29801.76 𝑁, 𝐹𝐹 = 49351.72 𝑁

𝑅𝐼 = 𝐹𝐼 tan(20) = 10846.95 𝑁

𝑅𝐹 = 𝐹𝐹 tan(14.5) = 12763.22 𝑁

𝐹𝑃1 + 𝐹𝑃2 = 𝐹𝐹 − 𝐹𝐼 cos(52) − 𝑅𝐼 sin(52) = 22456.41 𝑁

Taking movement from P2,

49351.72 × 626 − 26895.31 × 408

𝐹𝑃1 = = 12737.14 𝑁
1564

𝐹𝑃2 = 22456.41 − 12737.14 = 9719.27 𝑁

𝑅𝑃1 + 𝑅𝑃2 = 𝑅𝐼 cos(52) − 𝐹𝐼 sin(52) + 𝑅𝐹 = −16806.06 + 12763.22 = −4042.84 𝑁

Taking movement from P1,

18
 −16806.06 × 1156 + 12763.22 × 938
𝑅𝑃2 = = 27209.45 𝑁
1564

𝑅𝑃1 = −4042.84 − 27209.45 = −31252.29 𝑁

According to the figure 3: 𝐹1 = 𝐹𝐼 𝑐𝑜𝑠(52) + 𝑅𝐼 𝑠𝑖𝑛(52) = 26895.31 𝑁

𝑅1 = 𝐹𝐼 𝑠𝑖𝑛(52) − 𝑅𝐼 𝑐𝑜𝑠(52) = 16806.06 𝑁

Here forces are in 2 planes. Therefore, SFD and BMD diagrams should be drawn for both
planes.

First consider Z-Y plane,

Figure 5: SFD and BMD for Z-Y plane

𝑑
Shear force diagram can be draw easily. Bending movement is 𝑑𝑥 (𝑀) = −𝑠 from that,

0<x<0.408, 𝑀 = 9719.27 𝑥
19
x=0.408; 𝑀 = 3965.46 𝑁𝑚
0.408<x<0.626; 𝑀 = 37372.78𝑥 + 𝑐; Here c = -11282.63
x=0.626; 𝑀 = 12112.73 𝑁𝑚

Consider X-Y plane,

Figure 6: SFD and BMD for X-Y plane

𝑑
Shear force diagram can be draw easily. Bending movement is 𝑑𝑥 (𝑀) = −𝑠 from that,

0<x<0.408, 𝑀 = −27209.45𝑥
x=0.408; 𝑀 = −11101.46 𝑁𝑚
0.408<x<0.626; 𝑀 = −44015.51𝑥 + 𝑐; Here c = 6869.12
x=0.626; 𝑀 = −20684.59 𝑁𝑚

∴ 𝑀𝑠𝑢𝑚 = √𝑀𝑧2 + 𝑀𝑦2 = 23970.2 𝑁𝑚

20
 𝐹𝐹 𝐷𝐹 49351.72 × 0.245
𝑡𝑜𝑟𝑞𝑢ⅇ 𝑜𝑛 𝑠ℎ𝑎𝑓𝑡(𝜏) = = = 6045.59 𝑁𝑚
2 2

In this application environmental conditions aren’t severe because the propulsion system is
been sealed to prevent entering the water and perfume a heavy duty work so, factor of safety
is taken as 4.5 [3]. Also, AISI 1030 mild steel is selected as shaft material considering
strength and hardness properties [4]. Also, it’s used in gearbox shaft material in many
applications. Its strength values are,
Yield strength of AISI 1030 – 440 Mpa
Sear strength of AISI 1030 – 80 Gpa [5]

𝑦ⅇ𝑖𝑙𝑑 𝑠𝑡𝑟ⅇ𝑛𝑔𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡ⅇ𝑟𝑖𝑎𝑙 440

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙ⅇ 𝑏ⅇ𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟ⅇ𝑠𝑠(𝜎) = = = 97.78 𝑀𝑝𝑎
𝑆𝐹 4.5
𝑠ℎⅇ𝑎𝑟 𝑠𝑡𝑟ⅇ𝑛𝑔𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡ⅇ𝑟𝑖𝑎𝑙 80
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙ⅇ 𝑠ℎⅇ𝑎𝑟 𝑠𝑡𝑟ⅇ𝑠𝑠(𝜎) = = = 17.78 𝐺𝑝𝑎
𝑆𝐹 4.5
16
𝜏𝑚𝑎𝑥 = √(𝐾𝑚 𝑀𝑏 )2 + (𝐾𝑡 𝑇)2 ≤ 𝜏
𝜋𝑑3
16
𝜏𝑚𝑎𝑥 = √(1.5 × 23970.2)2 + (1 × 6045.59)2 ≤ 97.78 × 106
𝜋𝑑3
𝑑 ≥ 123.8 𝑚𝑚
16
𝜎𝑚𝑎𝑥 = [𝐾 𝑀 + √(𝐾𝑚 𝑀)2 + (𝐾𝑡 𝑇)2 ] ≤ 𝜎
𝜋𝑑3 𝑚
16
𝜎𝑚𝑎𝑥 = [1.5 × 23970.2 + √(1.5 × 23970.2)2 + (1 × 6045.59)2 ] ≤ 17.78 × 109
𝜋𝑑3
𝑑 ≥ 27.5 𝑚𝑚
Here Km and Kt values taken from considering rotating shaft with gradually applied load
(table 06)

Table 06: Recommended values for Km and Kt

21
Therefore, suitable diameter for lay shaft is 140 mm.

3.2 Reverse gear shaft

Figure 7: Forces on Reverse gear shaft

It can be taken F1 and R1 instead of FI and RI (As the calculation done in lay shaft).

𝐹1 = 26895.31 𝑁, 𝑅1 = 16806.06 𝑁

𝐹𝐺 = 23841.41 𝑁, 𝑅𝐺 = 𝐹𝐺 tan(14.5) = 6165.81 𝑁

Here: 𝐹𝑝3 = 𝐹1 − 𝐹𝐺 = 3053.9 𝑁 and 𝑅𝑃3 = 𝑅𝐺 − 𝑅1 = −10640.25 𝑁

Consider the X-Z plane:

22
 x

Figure 8: SFD and BMD for X-Z plane

𝑑
Shear force diagram can be draw easily. Bending movement is 𝑑𝑥 (𝑀) = −𝑠 from that,

0<x<0.272, 𝑀 = −26895.3𝑥
x=0.272; 𝑀 = −7315.52 𝑁𝑚
Consider X-Y plane:

23
 x

Figure 9: SFD and BMD for X-Y plane

𝑑
Shear force diagram can be draw easily. Bending movement is 𝑑𝑥 (𝑀) = −𝑠 from that,

0<x<0.272, 𝑀 = 16806.06𝑥
x=0.272; 𝑀 = 4571.25 𝑁𝑚

∴ 𝑀𝑠𝑢𝑚 = √𝑀𝑧2 + 𝑀𝑦2 = 8626.31 𝑁𝑚

𝐹𝑇 𝐷𝐼 29801.76 × 0.4
𝑡𝑜𝑟𝑞𝑢ⅇ 𝑜𝑛 𝑠ℎ𝑎𝑓𝑡(𝜏) = = = 5960.35 𝑁𝑚
2 2

AISI 1030 mild steel is selected as shaft material and the selected safety factor is 4.5 as the
lay shaft conditions are in the reverse gear shaft.
Yield strength of AISI 1030 – 440 Mpa
Sear strength of AISI 1030 – 80 Gpa [5]

𝑦ⅇ𝑖𝑙𝑑 𝑠𝑡𝑟ⅇ𝑛𝑔𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡ⅇ𝑟𝑖𝑎𝑙 440

𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙ⅇ 𝑏ⅇ𝑛𝑑𝑖𝑛𝑔 𝑠𝑡𝑟ⅇ𝑠𝑠(𝜏) = = = 97.78 𝑀𝑝𝑎
𝑆𝐹 4.5
24
 𝑠ℎⅇ𝑎𝑟 𝑠𝑡𝑟ⅇ𝑛𝑔𝑡ℎ 𝑜𝑓 𝑚𝑎𝑡ⅇ𝑟𝑖𝑎𝑙 80
𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙ⅇ 𝑠ℎⅇ𝑎𝑟 𝑠𝑡𝑟ⅇ𝑠𝑠(𝜎) = = = 17.78 𝐺𝑝𝑎
𝑆𝐹 4.5
16
𝜏𝑚𝑎𝑥 = √(𝐾𝑚 𝑀𝑏 )2 + (𝐾𝑡 𝑇)2 ≤ 𝜏
𝜋𝑑3
16
𝜏𝑚𝑎𝑥 = √(1.5 × 8626.31)2 + (1 × 5960.35)2 ≤ 97.78 × 106
𝜋𝑑3
𝑑 ≥ 90.53 𝑚𝑚

16
𝜎𝑚𝑎𝑥 = [𝐾 𝑀 + √(𝐾𝑚 𝑀)2 + (𝐾𝑡 𝑇)2 ] ≤ 𝜎
𝜋𝑑3 𝑚
16
𝜎𝑚𝑎𝑥 = [1.5 × 8626.31 + √(1.5 × 8626.31)2 + (1 × 5960.35)2 ] ≤ 17.78 × 109
𝜋𝑑3
𝑑 ≥ 19.82 𝑚𝑚
Therefore, suitable diameter for reverse gear shaft is 100 mm.

3.3 Input shaft.

It is same as the reverse gear shaft so the diameter of the shaft that selected is 100
mm.

3.4 Output shaft

Output shaft also like cantilever shaft. But it can’t be exactly saying where both bending
movement and torque will be maximum in same place. Therefore, a table use for those
calculation. All distances are measure from left end (P0) (according to the figure 02). Bending
movements and torque on output shaft at each position
Gear Distance Gear(diameter) Forces on Forces on BM (Y) BM (Z) BM Torque
from B2 (m) XZ (N) XY (N) (Nm) (Nm) (sum) (Nm)
(m) (Nm)

1 0.860 0.758 -49351.7 12763.2 - 3324.3 859.43 3433.6 18704.3

2 0.404 0.625 -31709 8200.5 - 11137.58 2877.37 11503.3 9909.06

3 0.218 0.505 -24080 6202.75 - 8426.71 2175.19 10463.44 6080.2

Table 07: Bending movements and torque on output shaft at each position

25
Impact of bending movement is bigger than torque, therefore only 2nd gear will be enough for
calculations
16
𝜏𝑚𝑎𝑥 = √(𝐾𝑚 𝑀𝑏 )2 + (𝐾𝑡 𝑇)2 ≤ 𝜏
𝜋𝑑3
16
𝜏𝑚𝑎𝑥 = √(1.5 × 11503.3)2 + (1 × 9909.06)2 ≤ 97.78 × 106
𝜋𝑑3
𝑑 ≥ 101.2 𝑚𝑚
16
𝜎𝑚𝑎𝑥 = [𝐾 𝑀 + √(𝐾𝑚 𝑀)2 + (𝐾𝑡 𝑇)2 ] ≤ 𝜎
𝜋𝑑3 𝑚
16
𝜎𝑚𝑎𝑥 = [1.5 × 11503.3 + √(1.5 × 11503.3)2 + (1 × 9909.06)2 ] ≤ 17.78 × 109
𝜋𝑑3
𝑑 ≥ 22 𝑚𝑚
Therefore, suitable diameter for output shaft is 110 mm. It’s taken considering standard saft
size.

4 Bearing selection
Rotating shafts need bearings to be fixed to the housing. Because it can reduce friction of
moving parts relative to another and give smooth rotation. When selecting a bearing it needs
to consider few things. Those are, installation space, load acting on shaft (radial, axial or
both), accuracy etc.

In this case only radial loads are acting because here only use spur gears. By
considering Radial load resistance, Vibration or impact load resistance, High speed
adaptability, High accuracy, Rigidity and Misalignment, the cylindrical roller bearing (NN-
NNU) type bearing was selected.[6]

4.1 Bearing for reverse gear shaft and input shaft

Both reverse gear and input shafts are operating under same forces, so the forces on
the bearing are same. Both shafts can include with the same type of bearing.

Forces on the bearing: - 𝐹𝑝3 = 3053.9 𝑁 and 𝑅𝑃3 = 10640.25 𝑁

Resultant force on the bearing = 11069.56 N

Bore diameter = 100 mm

Life of the machine (marine gear box) = 30000 h

26
 Table 08: Operating hours of different machines[7]

Shaft rpm = 1500 rpm

𝑙𝑖𝑓ⅇ 𝑜𝑓 𝑏ⅇ𝑎𝑟𝑖𝑛𝑔 = 1500 × 30000 × 60 = 2700 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟ⅇ𝑣

Reliability is assumed as 95%. Then,

𝐶 𝑝
𝐿𝑛𝑚 = 𝑎1 𝑎𝑠𝑘𝑓 𝐿10 = 𝑎1 𝑎𝑠𝑘𝑓 ( )
𝑃

Table 09: Values for adjustment factor[7]

Due to insufficient data of lubrication system and fatigue load askf will assume as 1. Also,
there only radial load acting on bearing due to that will 𝑃 = 𝑓𝑟 .

3
𝐶𝑟
𝐿5𝑚 = 2700 = 0.64𝐿10 = 0.64 ( )
11069.56

𝐶𝑟 = 178864.83 𝑁

27
 Table 10: Single row cylindrical roller bearings[7]

According to the table, NU 220 ECP bearing is selected.

4.2 Bearing for lay shaft

4.2.1 left end (figure 02)

Forces on the bearing: - 𝐹𝑝1 = 12737.14 𝑁 and 𝑅𝑃1 = 31252.29 𝑁

Resultant force on the bearing = 33748.19 N

Bore diameter = 140 mm

Life of the machine (marine gear box) = 30000 h

Shaft rpm = 1500 rpm

𝑙𝑖𝑓ⅇ 𝑜𝑓 𝑏ⅇ𝑎𝑟𝑖𝑛𝑔 = 1500 × 30000 × 60 = 2700 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟ⅇ𝑣

Reliability is assumed as 95%. Then,

𝐶 𝑝
𝐿𝑛𝑚 = 𝑎1 𝑎𝑠𝑘𝑓 𝐿10 = 𝑎1 𝑎𝑠𝑘𝑓 ( )
𝑃

Due to insufficient data of lubrication system and fatigue load askf will assume as 1. Also,
there only radial load acting on bearing due to that will 𝑃 = 𝑓𝑟 .

3
𝐶𝑟
𝐿5𝑚 = 2700 = 0.64𝐿10 = 0.64 ( )
33748.19

𝐶𝑟 = 545312.03 𝑁

28
 Table 11: Single row cylindrical roller bearings[7]

According to the table 11, NU 2228 ECML bearing is selected.

4.2.2 Right end (figure 02)

Forces on the bearing: - 𝐹𝑝2 = 9719.27 𝑁 and 𝑅𝑃2 = 27209.45 𝑁

Resultant force on the bearing = 28893.22 N

Bore diameter = 140 mm

Life of the machine (marine gear box) = 30000 h

Shaft rpm = 1500 rpm

𝑙𝑖𝑓ⅇ 𝑜𝑓 𝑏ⅇ𝑎𝑟𝑖𝑛𝑔 = 1500 × 30000 × 60 = 2700 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟ⅇ𝑣

Reliability is assumed as 95%. Then,

𝐶 𝑝
𝐿𝑛𝑚 = 𝑎1 𝑎𝑠𝑘𝑓 𝐿10 = 𝑎1 𝑎𝑠𝑘𝑓 ( )
𝑃

Due to insufficient data of lubrication system and fatigue load askf will assume as 1. Also,
there only radial load acting on bearing due to that will 𝑃 = 𝑓𝑟 .

3
𝐶𝑟
𝐿5𝑚 = 2700 = 0.64𝐿10 = 0.64 ( )
28893.22

𝐶𝑟 = 466864.17 𝑁

29
 Table 11: Single row cylindrical roller bearings[7]

According to the table 11, NU 2228 ECML bearing is selected.

4.3 Bearing for output shaft

Output shaft is differed from other. Because unlike others it rotates different speed
with different work condition. Where,

In 1st gear – 478 rpm

In 2nd gear – 904 rpm

In 3rd gear – 1471 rpm with different forces exerted on it.

Gear Speed Bearing forces Bearing forces Resultant force Percentage of

(rpm) on XZ on XY
on bearing work (%)
(N) (N)
(radial)/N

1 478 49351.7 12763.2 50975.38 10

2 904 31709 8200.5 32752.23 20

3 1471 24080 6202.75 24866.05 70

Table 12: Bearing load on output shaft

Bore diameter = 110 mm

Life of the machine (marine gear box) = 30000 h

∴ 𝑙𝑖𝑓ⅇ 𝑜𝑓 𝑏ⅇ𝑎𝑟𝑖𝑛𝑔 = (0.1 × 478 + 0.2 × 904 + 0.7 × 1471) × 30000 × 60 = 2265 𝑚𝑖𝑙𝑙𝑖𝑜𝑛 𝑟ⅇ𝑣

30
 2265 × 106
𝑎𝑣ⅇ𝑟𝑎𝑔ⅇ 𝑟ⅇ𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛 = = 1259 𝑟𝑝𝑚
30000 × 60

𝐿5𝑚 = 2265 = 0.64𝐿10

3 3 3
𝐶𝑟 47.8 𝐶𝑟 180.8 𝐶𝑟 1029.7
2265 = 0.64[( ) × +( ) × +( ) × ]
50975.38 1259 32752.23 1259 24866.05 1259

𝐶𝑟 = 394670.76 𝑁

Table 13: Single row cylindrical roller bearings[7]

According to the table 13, NJ 2222 ECP bearing is selected.

5 Keys and keyways design calculations

Keys and keyways are used to prevent relative motion between two components. In this
case gears should be fix in input shaft. Due to that it needs to use key and keyway. Form the
various types of keys, rectangular shank keys are used. Because they can prevent relative
motion also there are used in industry where gears and shaft use as well.[8]

Figure 10: a: keyway, b: key, c: key seat, d: keyed joint

31
5.1 Key and keyway in input shaft and reverse gear shaft.
For all the keys here use same material as shaft. Also, key should be stronger than shaft.
Otherwise, failure can happen in key. Therefore, factor of safety is taken as 1.5 which is less
than factor of safety on shaft. And shaft diameter is 100 mm,

Yield strength of AISI 1030 – 440 Mpa

Sear strength of AISI 1030 – 80 Gpa [5]

Table14: Proportions of standard parallel, tapered and gib head keys

Maximum torque transmits by the shaft = 5960.35 Nm

Considering failure of key from shearing,

𝜎𝑦𝑡 440
𝜏𝑚𝑎𝑥 = = = 146.67 𝑁/𝑚𝑚2
2 × 𝐹𝑆 2 × 1.5

𝑑 100
5960350 = 𝑙 × 𝑤 × 𝜏𝑘 × = 𝑙 × 32 × 146.67 ×
2 2

𝑙 = 25.4 𝑚𝑚

Considering failure of key from crushing,

𝑡 𝑑 18 440 100
5960350 = 𝑙 × × 𝜎𝑐𝑘 × = 𝑙 × × ×
2 2 2 1.5 2

𝑙 = 45.15𝑚𝑚
32
Therefore, key length is taken as 46 mm.

Effect of keyway,

𝑤 ℎ 32 9
ⅇ = 1 − 0.2 ( ) − 1.1 ( ) = 1 − 0.2 ( ) − 1.1 ( ) = 0.837
𝑑 𝑑 100 100

5.2 Key and keyway in lay shaft

Shaft diameter = 140 mm

Maximum torque transmits by the shaft = 6045.59 Nm

Considering failure of key from shearing,

𝜎𝑦𝑡 440
𝜏𝑚𝑎𝑥 = = = 146.67 𝑁/𝑚𝑚2
2 × 𝐹𝑆 2 × 1.5

𝑑 140
6045590 = 𝑙 × 𝑤 × 𝜏𝑘 × = 𝑙 × 40 × 146.67 ×
2 2

𝑙 = 14.72 𝑚𝑚

Considering failure of key from crushing,

𝑡 𝑑 22 440 140
6045590 = 𝑙 × × 𝜎𝑐𝑘 × = 𝑙 × × ×
2 2 2 1.5 2

𝑙 = 26.76 𝑚𝑚

Therefore, key length is taken as 27 mm.

Effect of keyway,

𝑤 ℎ 40 11
ⅇ = 1 − 0.2 ( ) − 1.1 ( ) = 1 − 0.2 ( ) − 1.1 ( ) = 0.856
𝑑 𝑑 140 140

5.3 Splines calculations for output shaft

Splines needs because gears on output shaft should be shifted. Therefore, it needs to find
out permissible pressure on spline is smaller than 6.5Mpa. here, number of splines are
selected as 30.

33
 Figure 11: Splines[9]
Maximum torque on shaft – 9909.06 Nm

d – 110mm

D – 137.5mm (1.25d)

1
𝑀𝑡 = 𝑝𝑚 ln(𝐷2 − 𝑑 2 )
8

1
9909.06 = × 𝑝𝑚 × 0.072 × 6 × (137.52 − 1102 ) × 10−6
8

𝑝𝑚 = 5.4𝑀𝑝𝑎 < 6.5𝑀𝑝𝑎

Therefore, selected spline for output shaft is safe.

6 Tolerances and clearance fit

In this case hole basis system fit is selected. As shown in table 22, H8/f7 clearance fit is
selected. From that information, clearance fit for shaft as follows (from table 16),

• Input shaft –
Hole = 100+0.054
−0 𝑚𝑚, Shaft= 100−0.036
−0.071 𝑚𝑚

• Lay shaft –
Hole = 140+0.063
−0 𝑚𝑚, Shaft= 140−0.043
−0.083 𝑚𝑚

• Reverse gear shaft –

Hole = 100+0.054
−0 𝑚𝑚, Shaft= 100−0.036
−0.071 𝑚𝑚

• Output shaft –
Hole = 110+0.054
−0 𝑚𝑚, Shaft= 110−0.036
−0.071 𝑚𝑚

34
Table 15: description of preferred fit[10]

35
 Table 16: Selected fit – hole basis[10]

7 Gear shifting mechanism

As described in the introduction, 3rd gear can handle all the requirements below its
maximum performance. It needs special cases like carefully driving and escorting etc, to shift
gears and it is done while propeller is in steady state. There are three separate livers are
jointed to the 3 gears and gears are disengage to the left side where the Figure 3 shows.

8 Lubrication selection
To find proper lubrication, Pitch line velocity of the lowest speed gear, feet per
minute (fpm) should be find out.

𝑉 = 18.97 × 60 × 3.28 𝑓𝑡𝑚𝑖𝑛−1 = 3733.3 𝑓𝑡𝑚𝑖𝑛−1

36
 7000
𝐾𝑖𝑛ⅇ𝑚𝑎𝑡𝑖𝑐 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑎𝑡 400 𝐶 = 𝑉25 = = 114.56
√𝑣

Therefore, the best lubrication is ISO 320.

Table 17: Selected fit – hole basis[11]

9 References
[1] “A_Textbook_of_Machine_Design_by_R_S_KHUR.pdf.”

[2] “Machine Design: LESSON 24 DESIGN OF SPUR GEARS-II.”

http://ecoursesonline.iasri.res.in/mod/page/view.php?id=125533 (accessed Dec. 06,
2021).

[3] “Factors of Safety.” https://www.engineeringtoolbox.com/factors-safety-fos-d_1624.html

(accessed Dec. 07, 2021).

[4] H. Loewenthal, “Design of Power- Transmitting Shafts,” p. 30.

[5] “AISI 1030 Carbon Steel (UNS G10300),” AZoM.com, Aug. 23, 2012.
https://www.azom.com/article.aspx?ArticleID=6531 (accessed Dec. 07, 2021).

37
[6] “Selection of bearing type | Basic Bearing Knowledge | Koyo Bearings /JTEKT
CORPORATION.” https://koyo.jtekt.co.jp/en/support/bearing-knowledge/3-0000.html
(accessed Dec. 08, 2021).

[7] “0901d196802809de-Rolling-bearings---17000_1-EN_tcm_12-121486.pdf.”

[8] “What are shaft keyways, its characteristics and benefits,” Engineering Product Design.
https://engineeringproductdesign.com/knowledge-base/keys-keyways/ (accessed Dec. 08,
2021).

[9] J. K. G. R. S. KHURMI, Machine design, no. I. 2000. doi: 10.1038/042171a0.

[10] “ANSI-B4-2-1978-Preferred-Metric-Limits-and-Fits.pdf.”

[11] “Lubrication Selection for Enclosed Gear Drives.”

https://www.machinerylubrication.com/Read/707/enclosed-gear-drives (accessed Dec.
09, 2021).

38