6.

GEARBOX AND SHAFT LAYOUT

Appropriate sizes for the housing of the gearbox is required so as a rough sketch of the gear box
may be created and hence to determine actual axial dimensions. The overall length as well as the
distance between the gears of the intermediate shafts is required so as to account for the fittings
and attachments which will be mounted to the shafts.

The diagram below (Figure 6.1) shows a layout of all three shafts accounting for the other
fittings to be mounted such as bearings. Since the gear widths have been determined, the bearing
widths may be estimated allowing for larger spaces for larger bearings on the intermediate shaft
where the bending moment shall be the maximum in the gearbox.

Small changes in bearing widths will have little to no effect on the force analysis of the gearbox
since the location of the reacting normal forces will only be altered by minuscule amounts. A
0.30 m allowance between the two gears on the countershaft is given. This is dictated by the
mounting requirements of the bearings as well as the spatial requirements of the input and output
shafts. Other small allowances have also been accounted for the retaining rings as well as the
protrusion behind the bearings.

Rough Layout :

Figure 6.1 Rough Layout for Gearbox

Force Analysis:

The diagrams below have been used to conduct the force analysis on the gearbox system.

!
!

!
The general layout and axial dimensions of the countershaft onto which two spur gears shall be
mounted has been determined. The gears and bearings are supported by shoulders and held in
place by retaining rings. The gear transmits torque through the keys and keyways mechanism.
The Tangential and Radial forces transmitted from the gears to the shaft may be determined as
shown below in Figure 6.2.

Figure 6.2 Free Body Diagram for Shaft 2

Wt12 = 2.39 kN Wr12= Wt12tan θ = 2.39 tan 20o = 0.87 kN

Wt43 = 4.09 kN Wr43= Wt43tan θ = 4.09 tan 20o = 1.49 kN

t and r represent the Tangential and Radial directions respectively and 12 and 34 represent the
forces exerted on Gear 1 and Gear 4 as well as the force exerted on Gear 2 and Gear 3
respectively.
! y = 0;
ΣF
r r
! ay − W12
R − W34 + Rby = 0

! ay + Rby = 2.36 k N
R

! ΣMAz = 0;

−0.87
! × 80 − 1.49  × 380  + Rby(460) = 0

! by = 1.38 k N
R

! ΣMAy = 0;

2.39
! × 80 − 4.09  × 380  + Rbz(460) = 0

! bz = 2.96 k N
R

! ay +  1.38 k N = 2.36 k N
R

R
! ay = 0.98 k N

! ΣFz =0

! 2.39 − 4.09 + 2.96 + RAz = 0

! Az = − 1.26 k N = !1.26 k N
R

(2) ( 2 )
t
d2 280
T
! =W
! 12 = 2.39 × = 334.6 Nm

Wt12 = 2.39 kN Wr12= Wt12tan θ = 2.39 tan 20o = 0.87 kN

Wt34 = 4.09 kN Wr34= Wt34 tan θ = 4.09 tan 20o = 1.49 kN

! ay = 0.98 k N
R ! az = 1.26 k N
R

! by = 1.38 k N
R ! bz = 2.96 k N
R
Shear Force Diagram and Bending Moment Diagrams

Figure 6.3. Shaft Dimensions

X-Y Plane:

A o V M

Ray

0 < x < 80

! ΣMo =0 ! y=0
ΣF

! ay(x) − M = 0
R ! ay −  V = 0
R

! 0.98 (x) −  M = 0 ! = 0.98 k N
V

! =  0.98 x
M
 `!

80 < x < 380

! ΣMo =0 ! y=0
ΣF
r r
! ay(x) − W12
R (x − 80) −  M = 0 ! ay − W12
R −  V = 0

! 0.98 (x) − 0.87 (x − 80) −  M = 0 ! = 0.11 k N

V

! =  0.11 x + 69.6
M

380 < x < 460

! ΣMo =0 ! y=0
ΣF
r r r r
! ay(x) − W12
R (x − 80) − W34 (x − 380) −  M = 0 ! ay − W12
R − W34 −V =0

! 0.98 (x) − 0.87 (x − 80) − 1.49 (x − 380) −  M = 0 ! = − 1.38 k N

V

! =   − 1.38 x + 635.8
M
X-Z Plane:



A o V M

Raz

0 < x < 80

! ΣMo =0 ! ΣFz =0

! az(x) − M = 0
R ! az −  V = 0
R

! 1.26 (x) −  M = 0 ! = 1.26 k N
V

! =  1.26 x
M

80 mm
A o V M

Raz

80 < x < 380

! ΣMo =0 ! ΣFz =0
t t
! az(x) − W12
R (x − 80) −  M = 0 ! az − W12
R −  V = 0

! 1.26 (x) − 2.39 (x − 80) −  M = 0 ! = − 1.13 k N

V

! = −  1.13x + 191.2
M
 Wt12

80 mm 300 mm
A o V M

Raz Wt34

380 < x < 460

! ΣMo =0 ! ΣFz =0
t t t t
! az(x) − W12
R (x − 80) − W34 (x − 380) −  M = 0 ! az − W12
R + W34 −V =0

1.26 (x)
! − 2.39 (x − 80) + 4.09 (x − 380) −  M = 0 V
! = 2.96 k N

! =  2.96 x − 1363
M
The Shear Force diagrams and Bending Moment diagrams (Figure 6.4 and 6.5) for the shafts are
given in the next two pages.

Figure 6.4 SFD and BMD Part 1

 !

334.6KNmm

Figure 6.5 SFD and BMD Part 2

Using the figures above, the total moment may be obtained by combining both planar torques as
vectors:
! total =   100.82 + 78.42 = 127.7 k Nmm
M
Moments at Point b and Point d may be given as follows:
! total,b =   109.22 + ( − 215.6)2 = 241.68 k Nmm
M

! total,d =   83.82 + ( − 179)2 = 197.65 k Nmm

M
At Point b, Bending Moment is the highest and hence, there is a stress concentration at the
shoulder and the torque present is given as follows:
At b, Ma = 241.68 kNmm , Tm = 334.6 kNmm , Mm =Ta = 0

Cold Drawn 1020 Steel with Sut=470MPa and Sy = 390MPa is to be used.

Surface Factor, ka:

 b
ka= a Sut

ka = 4.51 (470)-0.265

ka = 0.88

Size Factor, kb:

Assuming kb = 0.9 (This value is to be rechecked after the diameter is determined)

Loading Factor, kc:

0.125
kc (torsion) = 0.328 Sut = 0.707

Temperature Factor, kd:

kd = 1 (at Room Temperature)

Fatigue Stress Concentration Factor, kf:

kf = 1+ q (kt – 1 )

kfs = 1+ qshear ( kts – 1 )

r/d = 2/20 = 0.1

From Table 7-1, kt = 1.5 and kts = 1.7

From Figure 6-20

Notch Sensitivity, q = 0.77

From Figure 6-21

Notch sensitivity, qshear = 0.81

kf = 1 + 0.77 (1.5 – 1 )

kf = 1.385

kfs = 1 + 0.81 (1.7 – 1 )

kfs= 1.57

Reliability Factor, ke:

From Table 6-5, for a Reliability

Percentage of 99.9%:

Reliability Factor ke = 0.753.

From Figure 6-8,

S′e = 0.5Sut (Sut ≤ 1400 MPa)

= (0.5) (470) = 235MPa

Se:

Se = kakbkckdkekf S′e

Se = (0.88) (0.9) (1) (1) (0.753) (1.385) (235)

Se = 194.11 MPa
Diameter of the Shaft at Point B may be calculated using the D-E Goodman equation and
assuming Safety Factor, n =1.5.

! !

d=
1
0.5 3
16 × 1.5 1 2 0.5 1
( ) ( )
2 2 2
(! { [4(1.385 × 241.68) + 3 1.57 × 0 ] + [4(1.385 × 0) + 3 1.57 × 334  ] })
π 194.11 × 106 470 × 106

Hence, the minimum diameter, d = 34.51 mm

A standard size of 35 mm for diameter, d may be chosen.

D
Typical ! ratio for Support Shoulder is 1.2, hence, D = 1.2 × 35 = 42 mm.
d

A nominal diameter of 45 mm for the cold drawn shaft may be chosen to check whether the
previous estimate was suitable.

D 45
Hence, = = 1.29
d 35
 d 35 r 3.5
Assuming the Fillet Radius , r = ! =! = 3.5 mm so ! = ! = 0.1
10 10 d 35

kt = 1.6 (From Figure A-15-9)

q = 0.8 (From Figure 6-20)

Fatigue Stress Concentration Factor, kf

kf = 1+ q (kt – 1 ) = 1+ 0.8 (1.6 – 1 ) = 1.48

kts = 1.4 (Figure A-15-8)

qs = 0.82 (Figure 6-21)

kfs = 1+ qshear ( kts – 1 )

= 1+ 0.82( 1.4 – 1 )

= 1.328
Size Factor, kb = 1.24d-0.107 (2.79≤ d  ≤ 51 mm) from Diagram 6-20.

kb = 1.24(35)-0.107 = 0.85

ka = 0.88 (Unchanged)

kc = kd = 1 and ke = 0.753 (Unchanged)

Se = kakbkckdkekf S′e

= (0.88) (0.85) (1) (1) (0.753) (1.48) (235)

= 195.9 MPa

2  2
32k f Ma 16k fsTa
σa′  = [( ) +  3( ) ] where Ta = 0
πd 3 πd 3

2 
32k f Ma 32(1.48)(241.68) 2 
!= ( ) =! ( ) = 84.98 MPa
πd 3 π (0.035)3

2  2
32k f Mm 16k fsTm
σm′  = [( ) +  3( ) ] where Mm = 0
πd 3 πd 3

2
16k fsTm 16(1.328)(334.6) 2 
!=  3( ) = ! 3( ) = 91.42 MPa
πd 3 π (0.035)3

The fatigue failure criteria for the modified Goodman Line may be given as follows:

1 σ ′  σ ′  84.98 91.42
! =  a +  m !=  +  = 0.63
nf Se Sut 195.9 470

n
! f = 1.59 (Almost similar to Goodman Fatigue Safety Factor of 1.5)

The Yield Strength equation is used to check for yielding as follows:

 Sy Sy 390
n
! y=  =  =    = 2.21
σ′ma x σ′a  +  σ′m  84.98 + 91.42

Checking the diameter at the end of the keyway, just to the right of Point b and at the groove of
Point d. From the moment diagram, Moment, M at the end is estimated as 245 Nm.

Assuming the radius at the bottom of the key way will be according to the standard:

Since r
= 0.02
d

r = 0.02d = 0.02×35 = 0.7 mm

From Table 7-1:

kt = 2.14

kts = 3.0

From Figure 6-20 and Figure 6-21:

q = 0.63

qs = 0.7

kf = 1+ q (kt – 1 )

= 1 + 0.63(2.14 – 1)

= 1.72

kf s= 1+ q (kts – 1 )

= 1 + 0.7(3 – 1)

=2.4
Se = kakbkckdkekf S′e

Every factor is unchanged except kf,

Hence, Se = (0.88) (0.85) (1) (1) (0.753) (1.72) (235)

= 227.66 MPa

2  2
32k f Ma 16k fsTa
σa′  = [( ) +  3( ) ] where Ta = 0
πd 3 πd 3

2 
32k f Ma 32(1.72)(245) 2 
!= ( ) =! ( ) = 100.11 MPa
πd 3 π (0.035)3

2  2
32k f Mm 16k fsTm
σm′  = [( ) +  3( ) ] where Mm = 0
πd 3 πd 3

2
16k fsTm 16(2.4)(334.6) 2 
!=  3( ) = ! 3( ) = 165.22 MPa
πd 3 π (0.035)3

1 σa′  σm′  100.11 165.22

! =  +  !=  +  = 0.79
nf Se Sut 227.66 470

n
! f = 1.23

The keyway hence turns out to be much more critical than shoulder. The diameter may be
increased or a higher strength material may be used.
Using 1050 Cold Drawn Steel with Sut = 690MPa

Recalculating the factors that affect Sut :

Surface Factor, ka:

b
ka= a Sut

ka = 4.51 (690)-0.265

ka = 0.798

From Table 7-1:

kt = 2.14

kts = 3.0

From Figure 6-20 and Figure 6-21:

q = 0.7

qs = 0.76 kf = 1+ q (kt – 1 )

= 1 + 0.7(2.14 – 1)

= 1.798

kf s= 1+ q (kts – 1 )

= 1 + 0.76(3 – 1)

=2.52
Se = kakbkckdkekf S′e

Every factor is similar except kf, & ka

Hence, Se = (0.798) (0.85) (1) (1) (0.753) (1.798) (235)

= 215.81 MPa

2  2
32k f Ma 16k fsTa
σa′  = [( ) +  3( ) ] where Ta = 0
πd 3 πd 3

2 
32k f Ma 32(1.798)(245) 2 
!= ( ) =! ( ) = 104.65 MPa
πd 3 π (0.035)3

2  2
32k f Mm 16k fsTm
σm′  = [( ) +  3( ) ] where Mm = 0
πd 3 πd 3

16(2.52)(334.6)
2 2 
16k fsTm
!=  3( ) = ! 3( ) = 173.48 MPa
πd 3 π (0.035)3

1 σ ′  σ ′  104.65 173.48
! =  a +  m !=  +  = 0.66
nf Se Sut 215.81 690

n
! f = 1.51

Since the Goodman Criteria is conservative, the safety factor is deemed as being close enough to
1.5.

From the Torque Diagram, note that no torque is present at the groove. From the Moment
Diagram, Ma = 197.65 Nm, Mm = Ta = Tm = 0.

kf = kt = 5.0 as estimate above.

From Table 7-1:
32k f Mm
σ! a = !
πd 3
32(5)(197.66)
=!
π (0.035)3

= 234.79 MPa
Se 215.81
n
! f  =   = 
σa 234.79

= 0.92

The safety factor is deemed as being to low. By referring to the website <www.globalspec.com>,
appropriate groove specifications for a retaining ring for a shaft diameter of 35 mm is given as
follows:

Width, a = 2 mm,

Depth, t = 1.5 mm

Corner Radius at the bottom of groove, r = 0.3 mm.

From Table 7-1:

kt = 5.0

From Figure 6-20:

q = 0.62

kf = 1 + q(kt – 1)

= 1 + 0.5(5-1)

=3
 32k f Mm
σ! a = !
πd 3
32(3)(197.66)
=!
π (0.035)3

= 140.88 MPa

Se 215.81
n
! f  =   =  = 1.53
σa 140.88

At Point e, only bending is present and the moment is very small. However, the diameter is small
as well and the stress concentration factor is high for the sharp fillet required for a bearing. From
the Moment Diagram:

Ma = 42.52 MPa

Assuming d = 25 mm and fillet radius r to fit a typical bearing,

r
! = 0.02,   r = 25 × 0.02 = 0.5
d

From Figure 6-20:

q = 0.7

From Table 7-1:

kt = 2.7

kf = 1 + 0.7(2.7 – 1)

= 2.19
32k f Mm
σ! a = !
πd 3
32(2.19)(42.52)
=!
π (0.025)3

= 60.7 MPa

Se 215.81
! f  =  
n =  = 3.56
σa 60.7
With the diameters specified for the critical locations, trial values may be used for the rest of the
diameters, taking into account typical shoulder heights for bearing support.

Hence,

D1 = D7 = 25 mm

D2 = D 6 = 30 mm

D3 = D5 = 35 mm

D4 = 45 mm

The Bending Moment is much smaller on the left side of the shaft. Hence, D1, D2 and D3 could
be made smaller. Unless the weight of the gearbox is a critical factor, there is little to no
advantage in removing more material and the extra rigidity may be needed to keep deflections
small.