Design first level gear reducer report of

mechanical design

Name：Hasan md Mehedy
Hubei University of technology
 Introduction
Universal gear reducers can be divided in different ways. The introductory difference is now made
according to the size of counterreaction into two types the artificial reducers, which are most
generally exploited in practice( power transmissions) and low counterreaction reducers, with the
counterreaction size lower than 10 angular twinkles, which are used only in perfection mechanics,
as movement transmissions. The composition researches only artificial gear units. The farther
division is done according to the position of the gears on the spherical gear reducers and planetary
reducers. In this paper, only artificial gear reducers will be considered, although moment planetary
reducers are decreasingly used in places where at a slightly advanced price it's possible to achieve
large transmission rates and small confines. The spherical gear reducers can be divided into
reducers with resemblant and coextensive, or nearly coextensive shafts. In this paper considers
only single- stage reducers and they're made only as resembling shaft reducers
The further division of these gear reducers can be made according to the underpinning system with
radial, axial and radial- axial underpinning. According to the number of stages, reducers can be
divided as single, two, three andmulti-stage units, but this paper exploration only single- stage gear
units. Depending on the way of connection between the reducer and the electric motor, gear units
can be divided as classic with the input shaft and reducers with an appendage for IEC motors, when
client mounting electric motor or when reducers are delivered with IEC motor. Geared motors can
be delivered with special reducer electric motor or with standard IEC motor. Depending on the size
of the reducer, there are small( generally with axis height h< 100 mm), medium( 100< h< 500 mm)
and large reducers( h> 500 mm), so that the size of the gear reducer can also have a certain impact
on the final shape of the reducer. Although, there's an interest that all gear units within one reducer
family are identical to each other. So, in this paper, only medium- sized gears are considered, which
are generally most needed.
Analysis of housing design
According to the underpinning system, single- stage gear reducers can be produced in two ways with
or without special cover – intermediate connector. It's clear that only axial underpinning of the
corridor is carried out in one- piece casing of single- stage gear reducer. that only two manufacturers
produce gear units without an intermediate connector. All other manufacturers use this connector and
in that way, they achieve advanced gear rate. Grounded on the anatomized gearbox jackets, it can be
noticed that all manufacturers produce the jackets from cast iron. Only two of them( Bonfiglioli S,
Leroy Somer) use aluminium blends as material for jackets of the low axis heights of reducer. In this
way, they achieve a lower weight of their gear units and therefore better specialized characteristics
of their products.
The housing design of single-stage gearbox depends most on the shaft arrangement and mounting
method. According to this, there are gearboxes with horizontal with vertical and with free shaft
positions .

Fig.. The characteristic solution of foot-mounted single-stage gear reducer with the horizontal arrangement of
the shafts].

Mechanical Engineering Design

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considered discrete entities. Here, the leading string of words preceding the word design is merely a
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machine-component design, systems design, and fluid-power design. All of these phrases are
somewhat more focused examples of mechanical engineering design. They all draw on the same
bodies of knowledge, are similarly organized, and require similar skills.

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to assist in the solution of design problems. Inexpensive microcomputers and robust computer
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gathering information.2 Computational Tools Computer-aided design (CAD) software allows the
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Other geometric properties such as areas and distances between points are likewise easily obtained.
overall design scheme of transmission device

The mechanical transmission scheme of the belt conveyor used in this design is V-belt transmission and first-
stage closed gear transmission.
Select the type of motor
According to the working requirements and working conditions, three-phase asynchronous motors are
selected. The enclosed self-cooled structure has a voltage of 380V and Y series.
(2)Select the rated power of the motor
The performance parameters of the belt conveyor are selected from the sixth group of data in Table 1, namely:

Table 1

Conveyor working
Conveyor working tensionF/N Reel diameterD/mm
-1
speedv/m·s

1200 1.6 220

The power required by the working machine is：

P  Fv  1200N 1.6m / s  1.92kW

w
1000 1000
The total transmission efficiency from the motor to the working machine is:

 123245

Among them1 、2 、3 、4 、5 are the efficiency of V-belt drive, gear drive, rolling bearing,

elastic sleeve pin coupling and roller, respectively. Check out Appendix 3 of P459 in Mechanical

Foundation Select

1 =0.96 、2 =0.98(level 8 accuracy)、3 =0.99(a pair of ball bearings)、4 =0.995、

 5 =0.96，Therefore

  1 2 3 2 45  0.96  0.98  0.99 2  0.995  0.96  0.860966414352  0.862

5
Summing moments about the x axis of shaft AB in Fig. 3–1d gives
Mx = F(0.75) − 240 = 0
F = 320 lbf

The normal force is N = 320 tan 20° = 116.5 lbf.

Using the equilibrium equations for Figs. 3–1c and d, the reader should verify that: RAy = 192 lbf, RAz = 69.9 lbf,
RBy = 128 lbf, RBz = 46.6 lbf, RCy = 192 lbf, RCz = 69.9 lbf, RDy = 128 lbf, RDz = 46.6 lbf, and To = 480 lbf · in. The
direction of the output torque To is opposite ωo because it is the resistive load on the system opposing the
motionωo.

the net force from the bearing reactions is zero whereas the net moment about the x axis is (1.5 + 0.75) (192) +
(1.5 + 0.75) (128) = 720 lbf · in. This value is the same as Ti + To = 240 + 480 = 720 lbf · The reaction forces RE , RF ,
RH , and RI , from the mounting bolts cannot be determined from the equilibrium equations as there are too
many unknowns. Only three equations are available, Fy = Fz = Mx = 0. In case you were wondering about
assumption 5, here is where we will use it (see Sec. 8–12). The gear box tends to rotate about the x axis because
of a pure torsional moment of 720 lbf ·

The power required by the motor is

P
P 
d w 
1.92kW
2.18kW
 0.880

Because of the rated power of the motor Ped  Pd

Check Appendix 50 of "Mechanical Basics" P499 and select the rated power of the motor as

2.2kW, which meets the rated power of the motor.

(3) Determine the speed of the motor Working

speed of transmission roller shaft:

nw  v  60  1000 1.6m/s  60 1000  138.898 r / min

 D3.14 180mm
P459 of Mechanical Basics. The common transmission ratio of V-belt is i1 = 2 ~ 4, and the common
transmission ratio range of cylindrical gear transmission primary reducer is i2 = 3 ~ 5 (8-level
accuracy). According to the relationship between the total transmission ratio i of the transmission
device and the transmission ratios i1、i2、…in a is i=i1i2…in, it can be known that the
reasonable range of the total transmission ratio is i = 6 ~ 20.
nm
also because i  ，,1500/138.898=10.799 r/min
nw
Therefore, the selectable range of the motor speed is

700.284r/min  n  2334.28r/min
Synchronous speeds in this range are 750r / min, 1000r / min and 1500r / min.
 P499 and related information to get motor data and calculate the total transmission ratio, which are listed
in the table below:

Table 2

Solution Motor model Rated power Rotating Full load Motor KG price Transmission
KW speed speed ratio
1 Y100L1-4 2.2 1500 1420 38 760 12.166
2 Y90S-6 2.2 1000 910 63 1022 7.797
3 Y132S-8 2.2 750 710 79 800 6.083

In order to reduce the weight and price of the motor, the Y series motor with the synchronous speed of

1500r / min is selected from Table as Y100L1-4.

Technical data of the motor

（r/min）
（kw） Synchronize （r/min）
Rated
motor model Rated Rotating Full load Rated torque
torque
power speed speed

Y100L1-4 2.2 1500 1420 2.2 2.2

Calculation and distribution of the total transmission ratio of the transmission device

Total transmission ratio 12.166

Distribution of transmission ratios at all levels

The relationship between the transmission ratio of each level and the total transmission ratio is i=i1i2.
According to the transmission ratio range of the V-belt i1=2 ~ 4, and the initial selection of i1＝3.042, the
transmission ratio of the single-stage cylindrical gear reducer is 4, which corresponds to the transmission
ratio range of the cylindrical gear transmission's Single-stage reducer i2=3~5 (8 Level accuracy), and it is
consistent with the design of the transmission device consisting of a belt drive and a cylindrical gear reducer,

namely ibelt<igear

Calculate the motion and power parameters of the transmission

Calculate the input power of each axis

The output power of shaft 0 (motor shaft) is:

P0 =Ped =2.2kW

1 axis (reducer high speed axis) input power: from 0 axis to 1 axis, through V belt drive and a

coupling, so:

P1  Ped =2.18kW  0.96=2.092kW

Input power of 2 shafts (reducer low speed shaft): from 1 to 2 shafts, through a pair of bearings, a pair

of gears, and a pair of gears, so:

P2  P1  =2.092kW  0.98  0.99=2.007kW

Input power of 3 shafts (roller shaft): from 2 shafts to 3 shafts, through a pair of bearings and a

coupling, so:

P3  P2  =2.092kW  0.99  0.995=1.977kW

Calculate the speed of each axis

Speed of 0 axis (motor shaft):

n  n m  1420 r / m in
Speed of 1 shaft (high speed shaft of reducer):

-1
n1  n m / i1 r/min
Speed of 2 shafts (low speed shaft of reducer):

n2  n1 / i2  nm / i1 i2  473.33/4=116.700 r/min-1
Speed of 3 shafts (roller shaft):

n3  n2  n1 / i2  nm / i1 i2  116.700 r/min-1

Calculate the torque of each axis

Torque of shaft 0 (motor shaft):

2.2kW
M 0  9550 P0 / n0  9550   14.796N  m
1420 r / min
④ Torque of 1 axis (reducer high speed axis):

2.092kW
M 1  9550 P1 / n1  9550   42.758N  m
466.798r / min
⑤ Torque of 2 shafts (reducer low speed shaft):

2.029kW
 9550P2 / n2  9550   164.240N  m
M
2

116.700r / min
④ Torque of 3 shafts (roller shaft):

2.06kW
M 3  9550P3 / n3  9550   161.785N  m
116.700 r / min
transmission parts

(belt transmission and gear transmission)

Calculation of design power Pd

Pd  K A Ped

Pd  K A Ped  1.1  2.18 kW  2.39kW

(2) Select the belt type

The belt type of the ordinary V-belt is selected according to the design that the Z-type

V-belt should be selected.

(3) Determine the reference diameter of the pulley and verify the belt speed
Checked from Table 13-7 of "Mechanical Fundamentals" P298, the reference diameter of
the small pulley is 50 ～ 90mm (ddmin=50mm), then dd1= 80mm> ddmin. and get dd 2 =
250mm

Error check calculation of transmission ratio: (is elastic sliding rate)

d
d2 250
i误 = dd1 (1   )  80 (11%)  3.157  is Elastic sliding rate
ii 3.157  3.042
Tolerance i  1  100%   100%  3.8%＜5%
i1 3.042
Meet the requirements
Belt Speed

Belt speed V= 5.95m/s

It meets the requirements of5m/s<v<25~30m/s, so the belt speed is appropriate.

(4) Determine the center distance, the reference length of the belt, and check the angle of the small
wheel
according to the following formula：

0.7d d 1  d d 2   a0  2d d 1  dd 2 

Can get 0.7（80+250）  a0  2（80+250）

Then 231  a0  660，let a0 =500mm

Then 231  a0  660,choose a0 =500mm

so:

mm

Ld = 1600mm
:

a  a Ld  Ldo 500 1600 1532.813  533.59mm

0
2 2
d d
 180 o  57.3o 250  80  161.74 o ＞120o
o o
a 1  180  57.3 
d2 d1

a 533.59
Meet the requirements.

Number of bands

z  Pd  2.39  6.93
(P1 P1 ) K a KL (0.35  0.03)  0.95 1.16

(6) Determine the structure and size of the pulley

According to the selection conditions of the V-belt structure, the main shaft diameter of

Y100L1-4 motor is d = 28mm;

 Judging from "Mechanical Fundamentals" P293, "Structure of V-belt pulley": When 3d <dd1

(90mm) <300mm, H-shaped orifice plate type or P-shaped spoke plate type pulley can be used,

this time choose H-shaped plate type as the small belt wheel.

Because dd2> 300mm, E-spoke type pulley should be used.

In short, the small belt wheel selects the H-type orifice plate structure, and the large belt wheel

selects the E-type spoke structure.

(7) Determine the tensioning device of the belt
A tensioning device with a simple structure and convenient adjustment for
periodically adjusting the center distance is selected.

(9) Material of pulley

Use gray cast iron, HT200.
Design of transmission parts in reducer (gear transmission design)

Selection of gear material, heat treatment method and accuracy grade

Gear material, heat treatment method and tooth surface hardness

Because there is slight vibration in the load, the transmission speed is not high, and there is no

special requirement for the transmission size. It belongs to the general gear transmission, so

both gears can use soft toothed surface gears. Check Table 14-10 of "Machinery Basics" P322.

The small gear is made of No. 45 steel, quenched and tempered, and the hardness is 260HBS.

The large gear is made of 45 steel, hardened and tempered, and the hardness is 220HBS.

Primary selection of accuracy class

The reducer is a general gear transmission, and the peripheral speed will not be too large.

According to Table 5-7 of the "Basics of Mechanical Design" P145, the 8-level accuracy is

selected initially.

Gear design according to the contact fatigue strength of tooth surface

Because the reducer in this design is a closed gear transmission with a soft tooth surface, the
gear bearing capacity is mainly determined by the contact fatigue strength of the gear. Its
design formula is:

3.53ZE KM 1 u  1
d1  3 ( )2
H d  u

Determine the load factor K

 Because the gear transmission is a soft-tooth surface gear, the peripheral speed is not large,

and the accuracy is not high, and the gears are symmetrically arranged with respect to the

bearings. According to the nature of the motor and load, check Table 5-8 of "Basics of

Mechanical Design". The range of K is 1.4 ~ 1.6, and K = 1.5.

Pinion torque

2.092kW
M 1  9550 P1 / n1  9550   42.208 N  m  42208N  mm
473.33 r / min
Allowable stress in contact fatigue

P S H lim
ZN
Hm im

tooth surface hardness of the two gears, the ultimate stress after quenching
and tempering of 45 steel is found

 H lim1 =600MPa ，  H lim 2 =560MPa

Ⅱ) Contact fatigue life coefficient ZN

The formula of the number of stress cycles is N = 60 n jth，The working
life is 300 days per year and 8 hours per day.
th=(300×10×8)=24000h

N1=60×473.33×1×24000=6.81×108

N 6.81 108
 1.703108
1

N2 = i  4
Check Figure 5-31 of "Basics of Mechanical Design" P151, and allow some
pitting on the

gear surface.

ZN1=1.02 ZN2=1.15
Ⅲ) Minimum safety factor SHminin for contact fatigue
strength Check Table 5-10 of "Basics of Mechanical Design"
P151, SHmin = 1

Ⅳ) Calculate the allowable stress for contact fatigue .
HP

Substituting the above values into the allowable contact stress calculation
formula
 Z 600 1.02
 
p1 H lim1 N1  MPa  612MPa
 S 1
H min

 Z 560 1.15
 p2  H lim 2 N2  MPa  644MPa
S 1
H min
Tooth width factor
Because the gears in the gear transmission of this design are symmetrically arranged and are

soft-toothed surface transmissions, check Table 14-12 in "Machinery Basics" P326 to obtain the

range of tooth width coefficients from 0.8 to 1.1. Take  d  1.

Calculate pinion diameter d1

Because of  p 2   p1 ,  p1 should be substituted into the tooth surface

contact fatigue

design formula, get

2
3.53Z KM 1 u  1   3.53  189.8  1.5  42208 4  1 
d3( E
 3    mm  45.60mm
    612 
)2
1 u 1 4 
H d    
Peripheral speed v

 n1 d1   473.33  45.60
v1    1.13 m / s
60  1000 60 1000
Check Table 5-7 of "Basics of Mechanical Design" P145, v1 <2m / s, this gear drive uses 9-
level precision.
Selection of main parameters and calculation of geometric dimensions

Number of teeth

For closed soft-toothed surface gear transmission, z1 is usually selected between 20 and 40. In

order to make the coincidence degree larger, take z1 = 20, then z2 = iz1 = 80. Make the number of

teeth of the two gears prime to each other, and finally determine z2 = 81.

Modulus m
d 45.60
m 1
  2.28mm
z1 20
The standard modulus should be greater than or equal to the modulus calculated by the

above formula. Refer to Table 14-1 in "Machinery Basics" P311 and select the standard

modulus m = 3mm.

Indexing circle diameter d

d1  mz1  3 20mm  60mm

d 2  mz 2  3 81mm  243mm

center distance a
1 1
a ( d1  d 2 )  (60  243) mm  151.5mm
22
gear width b
 Gear width b2   d d1  1 60mm  60mm

Pinion width b1  b2  (5 : 10)mm  70mm

*
 0.25 ）
*
Calculation of other geometric dimensions（ ha  1， c

Tooth height ha  ha * m , Due to the normal gear, ha *  1

15

So ha  ha * m  1  3mm  3mm

Tooth root height h f  ( ha * c*)m due to normal teeth c*  0.25

So h f  ( ha *  c*) m  (1  0.25)  3mm  3.75mm

Full tooth height h  ha  h f  (2 ha *  c*) m  (2  1  0.25)  3mm  6.75mm

Tooth circle diameter d a1  d1  2 ha  60  6  66mm

d a 2  d 2  2 ha  243  6  249mm

Tooth root diameter

d f 1  d1  2 h f  60  2  3.75  52.5mm

d f 2  d 2  h f  243  2  3.75  235.5mm

(4) Tooth root check

The formula for checking the bending fatigue strength of tooth root is

Tooth shape coefficient YF

According to Z1 and Z2, check Table 5-11 in "Basics of Mechanical Design" P153, and get YF1＝

2.81，YF2＝2.24
Allowable bending fatigue stress calculation formula
Bending fatigue limit stress  F lim

According to the material, heat treatment method and hardness of the large and small gears, it

can be found from the MQ value line in Figure 5-33 of "Basics of Mechanical Design"

 Flim1 =180MPa ，  Flim 2 =170MPa

ⅱ） Bending fatigue life coefficient YN

6 8 6
According to N1=6.722 >310

and N2=1.681 10 > 310 , check Figure 5-34 of
"Basics of Mechanical Design" P156,

YN1=1 , YN2=1

Minimum safety factor SFmin for bending fatigue strength

This drive requires general reliability. Check Table 5-10 of "Principles of Mechanical Design"
P151, and take SFmin = 1.2.

Allowable stress for bending fatigue

The above parameters are substituted into the allowable bending fatigue stress formula to obtain

 = Flim1
Y = 180 1MPa=150MPa
FP1 S N1 1.2

Fmin

 = Flim2
Y =170 1MPa=141.67MPa
FP2 S N2 1.2
Fmin
Ⅴ) Check of root bending fatigue
strength

 2KT1 Y =2  1.5  42208  2.81MPa=32.94MPa  

F1 bmd F1 60360 FP1
1

  2KT1 Y  2  1.5  42208  2.24 MPa  26.25MPa  

F 2 bmd F2 60360 FP2
1

Therefore, the bending strength of the gear root is safe.

Design of the shaft

A shaft is a rotating member, usually of circular cross section, used to transmit power or motion. It provides the
axis of rotation, or oscillation, of elements such as gears, pulleys, flywheels, cranks, sprockets, and the like and
controls the geometry of their motion. An axle is a nonrotating member that carries no torque and is used to
support rotating wheels, pulleys, and the like. The automotive axle is not a true axle; the term is a carryover
from the horse-and-buggy era, when the wheels rotated on nonrotatingmembers. A nonrotating axle can readily
be designed and analyzed as a static beam, and will not warrant the special attention given in this chapter to the
rotating shafts which are subject to fatigue loading.

Shaft Materials
Deflection is not affected by strength, but rather by stiffness as represented by the modulus of elasticity, which
is essentially constant for all steels. For that reason, rigidity cannot be controlled by material decisions, but only
by geometric decisions. Necessary strength to resist loading stresses affects the choice of materials and their
treatments. Many shafts are made from low carbon, cold-drawn or hot-rolled steel, such as ANSI 1020-1050
steels

Design of high-speed shaft

Select material and heat treatment of shaft
45 steel, after quenching and tempering treatment, check Table 16-1 of Mechanical Foundation
P369 to get the allowable bending stress

 1   60MPa ， A  118 : 106 。

Preliminary calculation of shaft diameter

It can be known from the previous calculations: P1 = 2.09KW, n1 = 466.798r / min

Among them, A takes 112.

Considering that there is a keyway, the shaft diameter is increased by 5%, then

d=18.380  105%=19.29mm  22.4mm

Check Appendix 1 of Mechanical Foundation P458, take d = 25mm
Structural design of the shaft
The high-speed shaft is initially determined to adopt a gear shaft, that is, the gear and the shaft are
integrated into one. According to the installation and fixing requirements of the parts on the shaft,
the shaft structure is initially determined. With 7 shaft sections.
Section 1: This section connects the left shaft end of the pinion with the pulley. The diameter
of this shaft section is 25mm. Addendum 23 to P475, take this shaft extension L1 = 60mm.

Paragraph 2: Refer to P373 of Mechanical Foundation, take the shoulder height h as 1.5mm, then

d2 = d1 + 2h = 28mm.

Part of this shaft segment is used to install the bearing cover, and part of it extends out of the

box.

3: The bearing is installed in this section. The height h of the shoulder is 1mm, then d3 = d2 + 2h

= 30mm.

Use deep groove ball bearings. Check Appendix 24 of P476 for Mechanical Foundation. The

bearing code used here is 6306, with an inner diameter of 30mm and a width of 19mm. For the

purpose of fixing, the width of this section is 1 ~ 2mm smaller than the width of the bearing. Take

this length L3 = 17mm.

In order to prevent the gear and bearing from colliding with each other and to facilitate processing,

there must be a certain distance between the gear and the bearing. Taking the shoulder height as 2mm,

d4 = d6 = d3 + 2h = 33mm, and the length is 5mm. , Then L4 = L6 = 5mm.

the gear shaft section. It can be known from the pinion indexing circle diameter d = 60mm that d6 =

60mm. Because the width of the pinion is 70mm, L5 = 70mm. Segment 7: The bearings are installed

in this segment. The bearings selected are the same as those on the right, that is, d7 = 30mm and L7 =

17mm.

Can be calculated from the above, the span of the two bearings L = mm

The schematic diagram of the shaft section of the high-speed shaft is as follows:

Calculated by bending moment composite strength:

A、Circumferential force
2 M 1 2  42208
Ft 1    1406.93N
d1 60
B、 Radial force

F r 1  F t 1 tan   1406.93  tan 20 0  524.5N

Draw a simple diagram of the axial force

Plot vertical plane bending moment

Bearing reaction force:

F F  Fr1  518.8  259.4N

AY BY
2 2

F  F  Ft1  1425.3  712.65N

Az Bz
2 2
It is known from both sides that the bending moment of section C is also symmetrical. The

bending moment of section C in the vertical plane is

97 97
M c1  FAY   259.4   12580.9N  mm
2 2
Plotting moments in the horizontal plane

20

M  F  L  712.65 97  34563.5N  mm

c2 AZ 2 2

Draw the bending moment diagram

Mc1  ( MCV 1 2  MCH12 )  12580.9 2  34563.5 2  36782.01N  mm

Draw a twist

The torsional shear force generated by the torque changes according to the pulsating cycle,

taking α = 0.6,

aM 1  0.6  42758  25654.8N  mm

Plot equivalent bending moments

Equivalent bending moment at section C:

Mec  ( Mc 2  ( M 1) 2 )  36782.012  (0.6  42758) 2  44845.12N  mm

Checking the strength of the dangerous section C

The section with the largest combined bending moment on the shaft is located at C of the gear
3
rim, W＝0.1d4

 Ce  Mec  44845.12  12.48 MPa  [ 1 ]  60MPa

W 0.1  333
So the shaft strength is sufficient.

Design of low speed shaft

Select material and heat treatment of shaft
45 steel, after quenching and tempering treatment, check Table 16-1 of Mechanical Foundation
P369 to get the allowable bending stress

 1   60MPa ， A  118 : 106 。

 Preliminary calculation of shaft diameter
According to the previous calculations: P2 = 2.007KW, n2 = 116.700r / min
Calculate the shaft diameter formula:
P2
d2  A3
n
2

which is:

Among them, A takes 106.

P
2 2.007
d2A3  1063  27.36mm
n2 116.700
Considering that there is a keyway, the shaft diameter is increased by 5%, then

d 2  27.36  1.05  28.73mm

Check Appendix 1 of "Machine Foundation" P458, take d = 30mm

Structural design of the shaft

According to the installation and fixing requirements of the parts on the shaft, and considering the

structure of the high-speed shaft, the structure of the low-speed shaft is initially determined. With

6 shaft sections.
Stage 1: This stage is equipped with a coupling. The minimum diameter d1 = 32mm is selected at the
coupling. According to Appendix 32 of "Mechanical Foundation" P482, the elastic sleeve pin

J 32  82
coupling is used LT 6 . The diameter of the shaft hole is 32mm and the length of
J1B32 82
the shaft hole is 60mm. According to the length of the shaft hole of the coupling, and according
to Appendix 23 of P475 of Mechanical Foundation, the length of the shaft extension section (ie
section I) is L1 = 58mm.

Section 2: Check P373 of Mechanical Foundation, take the shoulder height h as 1.5mm, then d2 =

d1 + 2h = mm

Part of the length of this shaft segment is used to install the bearing cover, and part of it extends

out of the box.

Segment 3: Take the shoulder height h as 2.5mm, then d3 = d2 + 2h = 35 + 2 mm. This section is

equipped with bearings and sleeves. Use deep groove ball bearings. Check the mechanical

foundation P476 appendix 24. The bearing code used here is 6208, its inner diameter is 40mm,

and its width is 18mm. For the purpose of fixing, the width of this section is 1 ~ 2mm smaller than
the width of the bearing. Taking the sleeve length as 10mm, the length of this segment is L3 =

(18-2) + 10 + 2 = 28mm.

Stage 4: This stage is equipped with gears, taking the shoulder height h as 2.5mm, then d4 = d3 +

2h = mm. Because the width of the large gear is 60mm, then L4 = 60-2 = 58mm

Section 5: Take the shoulder height h as 2.5mm, then d5 = d4 + 2h = 50mm, the length is the

same as the sleeve on the right side, that is L5 = 10mm.

Section 6: The bearings are installed in this section. The bearings selected are the same as those

on the right, that is, d6 = 40mm and L6 = 17mm.

Can be calculated from the above, the span of the two bearings L =.18  2  10  60  98mm

The schematic diagram of the shaft section of the low-speed shaft is as follows:

Calculated according to bending moment composite strength

A、Circumferential force:

2M 2 2 164240
Ft 2    1351.770N
d2 243
B、Radial force:

F r 2  F t 2 tan   1351.770  tan 20 0  492N

FAX、FBY、FAZ、FBZ
Seek reaction FAX、FBY、FAZ、FBZ
F
F F   492  246N
r2

AY BY
2 2
F
F  F   1351.770  675.885N
t2

Az Bz
2 2
 From both sides of symmetry, it is known that the bending moment of section C

is also symmetrical. The bending moment of section C in the vertical plane is

Force diagram:

M F L  246 98  12054N  mm

c1 AY 2 2
The bending moment of section C on the horizontal plane is:

M  F L  675.885 98  33118.365N  mm

c2 Az 2 2
The resulting bending moment is:

M c  (M c12  M c 22 }  120542  33118.3652  35243.79N  mm

The torsional shear force generated by the torque changes according to the
pulsating cycle, taking α = 0.6 and the equivalent bending moment at section
C:

M ec  M c 2  (aM 2 )2  441362  (0.6  164240)2  104656.8N  mm

Checking the strength of the dangerous section C

The section with the largest combined bending moment on the shaft is located at C of the gear

3
rim, W＝0.1d4

Ce  
Mec 104656.8
    
3  11.48 Mpa<  1 b
W 0.1  45
So the shaft strength is sufficient.

Determine the lubrication and sealing of rolling bearings

Since the circumferential speed of the bearing is 1m / s <2m / s, the bearing should be filled with

grease for lubrication. Seals on the outside of rolling bearings are sealed with flanged bearing covers

and felt rings.

Back to the oil ditch

Because the bearings are lubricated with grease, an oil return groove is provided on the upper

surface of the box seat flange to improve the sealing performance at the split surface of the box.

Determine the installation position of the rolling bearing in the housing seat hole

Because the bearing is lubricated with grease, the distance from the inner end surface of the

bearing to the box is preferably 10mm, and an oil seal is provided to prevent the grease from being

washed away by the hot oil that is extruded or splashed out when the gears mesh.

Determine the width L of the bearing housing hole

 , Is the wall thickness of the box seat, and is the wrench space required for the connection

bolts of the box seat and box cover, which is obtained by checking the mechanical foundation

table 19-1, taking = 8mm, C1 = 18mm, C2 = 16mm, L = 8 + 18 + 16 + 8 = 50mm.

Determine the position of the shaft protruding outside the box

Adopt flange type bearing cover, LH3 elastic stud coupling, high speed shaft bearing cover adopts

GB / T5782 M6 30 bolts, low speed shaft adopts GB / T5782 GB / T5782M8 35 bolts for

convenience In the case of external parts, the bearing cap can be easily removed. Check Appendix

33 of the "Mechanical Foundation" to get the length of A and B, then:

High-speed shaft: L1> (A-B) = 35-23 = 12mm; Low-speed shaft: L2> (A-B) = 45-38 = 7mm

According to the setting of L1 = 60mm for the high-speed shaft and the low-speed shaft

L2  58mm , it can meet the requirements.

Determine the axial dimension of the shaft High-

speed shaft (unit: mm):
 Shaft D1 D2 D3 D4 D5 D6 D7

diameter 25 28 30 33 60 33 25

Shaft L1 L2 L3 L4 L5 L6 L7

length 60 60 17 5 70 5 17

Low-speed shaft (unit: mm):

Shaft D1 D2 D3 D4 D5 D6

diameter 32 35 40 45 50 40

Shaft L1 L2 L3 L4 L5 L6

length 58 60 28 58 10 17

calculation of rolling bearings

The terms rolling-contact bearing, antifriction bearing, and rolling bearing are all used to describe that class of
bearing in which the main load is transferred through elements in rolling contact rather than in sliding contact.
In a rolling bearing the starting friction is about twice the running friction, but still it is negligible in comparison
with the starting friction of a sleeve bearing. Load, speed, and the operating viscosity of the lubricant do affect
the frictional characteristics of a rolling bearing. It is probably a mistake to describe a rolling bearing as
“antifriction,” but the term is used generally throughout the industry. From the mechanical designer’s
standpoint, the study of antifriction bearings differs in several respects when compared with the study of other
topics because the bearings they specify have already been designed. The specialist in antifriction-bearing
design is confronted with the problem of designing a group of elements that compose a rolling bearing: these
elements must be designed to fit into a space whose dimensions are specified; they must be designed to receive a
load having certain characteristics; and finally, these elements must be designed to have a satisfactory life when
operated under the specified conditions. Bearing specialists must therefore consider such matters as fatigue
loading, friction, heat, corrosion resistance, kinematic problems, material properties, lubrication, machining
tolerances, assembly, use, and cost. From a consideration of all these factors, bearing specialists arrive at a
compromise that, in their judgment, is a good solution to the problem as stated.
 The bearing life recommended according to "Mechanical Fundamentals" P437 is best to be the

same as the life of the reducer. Take 10 years and calculate 300 days in a year.

T h=(300×10×8)=24000h

Checking of high-speed bearings

The selected bearing is a 6306 deep groove ball bearing.

The equivalent dynamic load of the bearing is

P  fd (XFr  YFa )

Check from Table 18-6 in "Mechanical Fundamentals" P407, fd = 1.2 ~ 1.8, fd = 1.2.

Because Fa1 = 0N and Fr1 = 518.8N, then

Checking Table 18-5 in "Mechanical Fundamentals" shows that X = 1, Y = 0.

P  f d XFr 1  1.2  1 518.8  622.56N  0.62256KN

Check Table 18-3 in "Mechanical Fundamentals" p406: ft = 1,

Checking "Machinery Basics" p405: The life index of deep groove ball bearings is = 3,

Cr= 20.8KN；
6  6 3 6
Then L  10 ( f t Cr )  10 (1 20800 )  1.3 10 h  24000h
10h
60n2 P 60  466.798 622.56
So the expected life is sufficient and the bearings meet the requirements.

Check of low speed bearings Use 6208

deep groove ball bearings.

The equivalent dynamic load of the bearing is P  fd (XFr  YFa )

Check from Table 18-6 in "Mechanical Fundamentals" P407, fd = 1.2 ~ 1.8, fd = 1.2.

Because Fa2 = 0N and Fr2 = 492N, then

Check Table 18-5 of "Mechanical Foundation" P407, X = 1, Y = 0.

P  f d XFr  1.2  1  745.09  590.405N

 Check Table 18-3 in "Mechanical Fundamentals" p406: ft = 1,

Checking "Machinery Basics" p405, the life index of deep groove ball bearings is 3, Cr =

22.8KN;

6

6 3 6
Then L10h  10 ( f tC )  10 (1 22800 )  8.2 10 h  24000h
60n P 60 116.7 590.405
So the expected life is sufficient and the bearings meet the requirements.

coupling and its check calculation

Types and specifications of selection keys

The circumferential fixing of the parts on the shaft uses the A-shaped ordinary flat key, and the

coupling uses the B-shaped ordinary flat key.

High-speed shaft (refer to "Principle of Machinery" p471, Appendix 17, "Pocket Mechanical Designer's

Manual" p835, Table 15-12a): According to the shaft diameter at the connection between the pulley and

the shaft is 25mm, the shaft length is 60mm. Section size b = 8mm, h = 7mm

Take the key length according to the wheel width L = 40mm High-speed

gears are co-manufactured with shafts and belong to gear shafts.

Low-speed shaft:

According to the shaft diameter at the installation gear, check the cross-sectional dimensions of the

key, and take the key length according to the hub width.

According to the shaft diameter where the coupling is installed, check the cross-sectional

dimensions of the key and take the key length L = 50mm.

Take the key length L = 72mm according to the width of the hub (the length is 10mm smaller than

the length of the hub)

Check the strength of the bond

Check of the key at the high speed shaft end:
Force on the key:

F  2 M  2  1000  42.758  3420.64N

d 25
Shear strength of the bond

   (0.6 ~ 0.8)   60 ~ 80MPa

F F 3420.64
    MPa  10.7 MPa  [ ]  60MPa
A bl 8  40

The bond has sufficient shear strength.

Extrusion strength of the coupling

 F 2 F 2  5179.76
 e＝ ＝ ＝  41.11MPa<  e   90MPa <
Ae hl7  36

e  F  2 F  2  3420.64 MPa  24.4 MPa  [ e ]  (17. ~ 2.0)  60  102 ~ 120MPa

Ae hl 740
The compressive strength of the coupling is sufficient.

Check of two keys of low speed shaft

A. Check of the keys of the low-speed shaft-mounted gear shaft section:

Force on the key:

F  2 M  2  1000 164.240  7299.56N

d45
Bond shear strength
F F 7299.56
    MPa  13.0 MPa  [ ]  60MPa
A bl 14  40
The bond has sufficient shear strength.

Extrusion strength of the coupling

e  F  2 F  2 7299.56 MPa  40.6 MPa  [ e ]  (17. ~ 2.0)  60  102 ~ 120MPa

Ae hl 9 40
The compressive strength of the coupling is sufficient.
B. Check of the key at the low speed shaft end:
Force on the key:

F  2 M  2  1000 164.240  10265N

d32
Bond shear strength
F F 10265
    MPa  20.53 MPa  [ ]  60MPa
A bl 10  50
The bond has sufficient shear strength.

Extrusion strength of the coupling

e  F  2 F  2 10265 MPa  51.3 MPa  [ e ]  (17. ~ 2.0)  60  102 ~ 120MPa

Ae hl 8  50
The compressive strength of the coupling is sufficient.
6, torque check of the coupling
Low speed shaft:
 J 32  82
Select the elastic sleeve pin coupling LT 6 , check Appendix 33 of "Machine
J1B32 82
Basics" P484, the allowable speed [n] = 3800r / min

Then n2 = 116.7r / min <[n]

So meet the requirements.

basic structure of the reducer

Structural design of gears
Pinion: According to the mechanical dimensions of P335 and the gears designed above, it can

be seen that the diameter of the pinion root circle is 52.5mm, and according to the size h of
the shaft selection key is 7, the distance between the root circle and the bottom of the keyhole
52.5  33  7
of the shaft hole x =  6.25 mm, and 2.5, m  2.5  3  7.5mm there are
n
2
x<2.5 mn , so the gear shaft structure should be used.

Combined design of rolling bearings

The span of the high-speed shaft is L = L1 + L2 + L3 + L4 + L5 = 60 + 60 + 17 + 5 + 70 + 5 +

17 = 234mm. It adopts a discrete solid structure to axially fix the shaft.

The span of the low-speed shaft is L = L1 + L2 + L3 + L4 + L5 = 58 + 60 + 28 + 58 + 10 + 17 =

231mm, and the shaft system is axially fixed with a separate solid structure.

Matching of rolling bearings

The shaft tolerance zone of the high-speed shaft is j6, and the hole tolerance zone is H7.

The shaft tolerance zone of the low speed shaft is k6, and the hole tolerance zone is H7.

High-speed shaft: journal cylindrical tolerance / P 6 = 2.5, housing hole / P 6 = 4.0;

Face runout shaft shoulder / P 6 = 6, housing hole / P 6 = 10.

Low-speed shaft: journal cylindrical tolerance / P 6 = 4.0, housing hole / P 6 =

6; Face runout shaft shoulder / P 6 = 10, housing hole / P 6 = 15.

The shaft mating surface Ra is selected from IT6 mill 0.8, and the end surface is selected from IT6

mill 3.2; The mating surface Ra of the shell is selected from the IT7 car 3.2, and the end surface is

selected from the IT7 car 6.3.

Disassembly of rolling bearings

When installing, hit the mounting sleeve with a hammer; in order to facilitate disassembly, a sufficient
height h is exposed at the shoulder of the shaft, and sufficient axial space L must be left

to place the hook of the disassembler.

Selection and calculation of bearing cover

Selection of bearing cover:

The flange type bearing cover is selected, which is made of gray cast iron HT150 and fixed on the box with
screws. Among them, the shaft extension end uses a transparent cover, and the non-shaft extension end uses a
stuffing cover.
Size calculation
Calculation of bearing cover (through cover) at shaft extension
A. High-speed shaft:
The selected bearing is a 6306 deep groove ball bearing with an outer diameter of D = 72mm. The
bearing cover structure used is the structure of a in the flanged bearing cover. Checking the
calculation formula of P423 in Mechanical Foundation: Screw diameter d3 = 8, number of screws
n=4
d0d31819
D 0  D  2.5 d 3  72  2.5  8  92
D 2  D 0  2.5d 3  92  2.5  8  112
e  1.2 d 3  1.2  8  9.6
e1  e, e1  9.6，e1＝10
D 4＝D -（10～15），D4＝72-12＝60
D5 ＝D 0  3d 3  92  3  8  68
D6D(2~4)72270
m＝e1＝10

B. Low-speed shaft:

The selected bearing is a 6208 deep groove ball bearing with an outer diameter D = 80mm.

Dimensions are:

Screw diameter 8, number of screws 4

d0d31819

D 0  D  2.5d 3  80  2.5  8  100

D 2  D 0  2.5 d 3  100  2.5  8  120
e  1.2 d 3  1.2  8  9.6
e1  e, e1  9.6，e1＝10
D4＝D-（10～15），D4＝80-15＝65
D5 ＝D 0  3d 3  100  3  8  76
D6D(2~4)80278
m＝e1＝10
The diagram is as follows:

Dimension calculation of bearing caps at non-shaft sections: The dimensions of the caps on the
high-speed shaft and the low-speed shaft are the same as those of their through-caps.

Lubrication and sealing

Gear lubrication

Oil immersion lubrication is adopted, and the oil immersion depth is one tooth height, but not less

than 10mm.

Lubrication of rolling bearings

Because the circumferential speed of the bearing is 1m / s <2m / s, the bearing is filled with grease

for lubrication.

Selection of lubricant

The gear is made of common industrial gear oil, and the bearing is made of calcium-based grease.

Selection of sealing method

The inside of the box is sealed with an oil retaining plate. The outer seal of the box is a flanged

bearing cover. A non-shaft end is used for the non-shaft extension. A cover is used for the shaf

extension. Both are sealed by gaskets. In addition, a felt ring is required at the shaft extension for

the cover Seal it.

 Conclusion

It is clear that contemporary gear reducers have aesthetic requirements in addition to functional

ones, independent of manufacturing complexity and material consumption. Whether or not the

gear reducer is housed inside the machine and is frequently hidden from view, its aesthetic appeal

becomes crucial. A nice gearbox will always catch the eye of the customer considering their

purchase, so while gear reducers are becoming more and more similar in terms of quality,

technical features, and cost, special attention should be paid to the design of the gear units.

Research and observation of derived gearbox solutions made by top global manufacturers lead to

this conclusion

APPENDIX
Solidwork/ CAD Design Based on design Calculation and 3D Design

Bearing cover 1
Bearing cover 2

Bearing cover 3

Bearing
Check Plate

Gear

Screw
 Shaft

Hosing Case

Housing Cover
 Final Design

Design Implementation by Hand as per Teacher’s Requirement’s

 References

[1] Fan Sichong, editor. Mechanical Foundation (for non-machine majors). Beijing:
Machinery Industry Press, 2005
[2] Editor Sun Jiandong. Basics of Mechanical Design. Beijing: Mechanical Industry Press, 2004
[3] Wang Kun, He Xiaobai, Wang Xinyuan, editor. Curriculum Design of Mechanical
Design. Beijing: Higher Education Press, 1996
[4] Shen Lenian, Chief Editor Liu Xiangfeng. Basics of Mechanical Design. Beijing:
Tsinghua University Press, 1996
[5] Wu Zongze, editor of Xiao Liying. Mechanical design study guide. Beijing: Mechanical
Industry Press, 2003
[6] Mechanical Design Manual (software version) V3.0 (download online)