Executive Summary of Design and Fabrication of Speed Reducer

As per the instruction the gear box is not using the liquid fluid so in that case the minimum maintenance is required, secondly the shaft front end is 3 time of the diameter of the Shaft. Taking about the part of shaft all are the as per requirement and all includes the standard sizes. More of them are solid in shape and circular in their physical properties. Input and the out of shaft is facing the each other but in the opposite direction and both are the 90 degree parallel in direction.

Gearbox shaped speed reducer is the final requirement by looking the up factor of instruction like size and shape and other speeding factors. These are the things depend on the customer’s requirement that what he requires and what are the output the customer wants. All are the design work will be done by the design analysis and as per the material it has depend upon the availability and the customer’s requirement and depend on the costing factor. All the analysis later on done in the practical form.

As the speed reducer works principle is to reduction of the speed by designing and analysis of the speed reducer. Speed reduction is also depending on the different factors like design and dimensions as well. Design of the gearbox speed reduction is free of other external power and other resources, which will work according the design, dimensions analysis, and meet the customer’s requirement.

Introduction of Design and Fabrication of Speed Reducer

Reducer is a kind of independent closed transmission device between the prime mover and the working machine. In addition, it is used to reduce the speed and increasing the working torque to meet the needs of the customer’s requirement and output designing. In some of the cases the reducer is also used to increasing the speeding of the output end but it is totally depend upon the design and dimension detail but that is not the major concern at all.

When choose the most suitable reducer you have to more depend upon the working environment and the technical parameters that has been used later on. Factors like machine performance, economy, and other factors as well.

Gear reducer is generally divided into the general and special ones but both are the different in the types and the characteristic point of view. Therefore, both design and dimension details are different. Reducer technology in the world has been introduces in the 1970 and 1980’s and it is closely integrated with the development of the new technological revolution.

Project Classification of Design and Fabrication of Speed Reducer

This project is include the design and fabrication of the speed reducer. First part is the design and dimension analysis and other part is the practically implementing such as the welding, milling, and others as well. The basic need of this project is the customer’s requirement that is on the top priority thing and then on the second skillful number of team is required who has the skills in design and layout the complete project. Internal working is also required for this project like (gear set and chain and sprocket).

The Use of the Classification of the Gear speed Reducer of Design and Fabrication of Speed Reducer

First gear speed reducer can be divided into the universal and dedicated speed reducer. These are the two categories according to the design and application analysis. In addition, the characteristic the design and the used of them are not the same with each other. In the 70 and 80 year of the current century, the reducer technology in the world has been greatly developed and is closely integrated with the development of a new technological revolution

depending upon the customer requirements. As per the requirements the design is also, include the dimension of each part of the gearbox speed reducer. In addition, the market availability is also necessary.

Appendix and Calculation of Design and Fabrication of Speed Reducer

Symbols:

d=shaft diameter, mm

n=speed, rpm

m=module, mm

P=power, kW

w=width of keyhole, mm

L=length of keyhole, mm

T=torque, N∙m

TV=train value

D=pitch diameter, mm

Wet=tangential force

W_r=radial force

ϕ=pressure angle, degrees

P_d=dynamic force

f_N=speed factor

f_L=life factor

C=basic dynamic load rating, N

N=number of teeth

Train Value:

TV= (product of number of teeth in the driven gears)/(product of number of teeth in the driving gears)

TV=3.15

TV=63/20= (9×7)/ (4×5) = (45×35)/ (20×25)

TV=45/20×35/25=N_2/N_1 ×N_4/N_3

N_1=20

N_2=45

N_3=25

N_4=35

Module:

For safety and geometric purposes, choose module 2 gears,

m=D/N

D=N×m

D_1=20×2

D_1=40 mm

D_2=45×2

D_2=90 mm

D_3=25×2

D_3=50 mm

D_4=35×2

D_4=70 mm

Main Shaft Diameter:

From Machinery’s Handbook

d=∛ ((1.77×〖10〗^6 P)/n)

d=∛ ((1.77×〖10〗^6 (2.25))/2000)

d=12.58 mm

d=12.7 mm (standard)

Width of the keyhole:

Assuming the same material as the shaft

w=d/4

w=12.7/4

w=3.175 mm

Length of the keyhole:

Assuming the same material as the shaft

L=1.2d

L=1.2(12.7)

L=15.24 mm

Main Shaft Torque:

T=P/2πn

T= (2.25(1000))/2π (2000/60)

T=10.74 N∙m

Tangential Force of Gear:

W_t=T/ (D⁄2)

W_t=10.74/ (0.04⁄2)

W_t=537 N

Radial Force of Gear:

W_r=W_t  tan⁡ϕ

W_r=429.6 tan⁡〖20°〗

W_r=195.45 N

Force on Bearing:

P_d=√ (〖97.73〗^2+〖268.5〗^2) =285.73 N

For multipurpose gearing, take L=10000 hours;

f_L=2.7

f_N=0.25

Required Basic Dynamic Load Rating:

C=P_d f_L f_N

C= (285.73) ((2.7)) ⁄ ((0.25))

C=3085.88 N

Counter Shaft Speed:

n_1 N_1=n_2

(2000)(20)=n_2 (45)

n_2=888.9 rpm

Counter Shaft Diameter:

From Machinery’s Handbook

d=∛ ((0.83×〖10〗^6 P)/n)

d=∛ ((0.83×〖10〗^6 (2.25))/888.9)

d=12.81 mm

d=15.875 mm (standard)

Counter Shaft Torque:

T=P/2πn

T= (2.25(1000))/2π (888.9/60)

T=24.17 N∙m

Tangential Force of Gear:

W_t=T/ (D⁄2)

W_t=24.17/ (0.09⁄2)

W_t=537.11 N

Radial Force of Gear:

W_r=W_t  tan⁡ϕ

W_r=537.11 tan⁡〖20°〗

W_r=195.49 N

Tangential Force of Pinion:

W_t=T/ (D⁄2)

W_t=24.17/ (0.05⁄2)

W_t=966.8 N

Radial Force of Pinion:

W_r=W_t  tan⁡ϕ

W_r=966.8 tan⁡〖20°〗

W_r=351.89 N

Force on Bearing A:

P_d=√ (〖86.01〗^2+〖236.33〗^2 )=251.49 N

For multipurpose gearing, take L=10000 hours;

f_L=2.7

f_N=0.34

Required Basic Dynamic Load Rating:

C=P_d f_L f_N

C= (251.49) ((2.7)) ⁄ ((0.34))

C=1997.12 N

Force on Bearing D:

P_d=√ (〖242.41〗^2+〖666.02〗^2) =708.76 N

For multipurpose gearing, take L=10000 hours;

f_L=2.7

f_N=0.34

Required Basic Dynamic Load Rating:

C=P_d f_L f_N

C= (708.76) ((2.7)) ⁄ ((0.34))

C=5628.39 N

Output Shaft Speed:

n_3 N_3=n_4 N_4

(888.9)(25)=n_4 (35)

n_4=635 rpm

Output Shaft Diameter:

From Machinery’s Handbook

d=∛ ((0.83×〖10〗^6 P)/n)

d=∛ ((0.83×〖10〗^6 (2.25))/635)

d=14.33 mm

d=15.875 mm (standard)

Width of the keyhole:

Assuming the same material as the shaft

w=d/4

w=15.875/4

w=3.96875 mm

Length of the keyhole:

Assuming the same material as the shaft

L=1.2d

L=1.2(15.875)

L=19.05 mm

Output Shaft Torque:

T=P/2πn

T= (2.25(1000))/2π (635/60)

T=33.84 N∙m

Tangential Force of Gear:

W_t=T/ (D⁄2)

W_t=33.84/ (0.07⁄2)

W_t=966.86 N

Radial Force of Gear:

W_r=W_t  tan⁡ϕ

W_r=966.86 tan⁡〖20°〗

W_r=351.91 N

Force on Bearing:

P_d=√ (〖175.96〗^2+〖483.43〗^2) =514.46 N

For multipurpose gearing, take L=10000 hours;

f_L=2.7

f_N=0.37

Required Basic Dynamic Load Rating:

C=P_d f_L⁄f_N

C= (514.46) ((2.7)) ⁄ ((0.37))

C=3754.17 N