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supported beam with a mid-mounted load is given by y WL3 48EI

6006 would be suitable with a considerable margin of safety. It is worth considering worst case usage. If the machine was operated continuously for the warranty period and other components did not fail, the design life would be 2850 60 24 365 1.5 2.25 109 revolutions Using this figure, the required basic dynamic load rating is 3798 N. Selecting a low-carbon, cold drawn steel for the key with a yield strength of 350 MPa, assuming a square key of 4 4 mm and setting N 4 for this application, the necessary key length is given by L 4TN 4 31.8 4 DW y 0.03 0.004 350 106

Taking the total mass of the gear and the shaft located at mid-span the deflection is y 29.1 0.13 48 200 109 0.034/64

7.624 108 m This is a very small deflection indicating that slope of the shaft, at the bearings, and deflection, are unlikely to be a problem in this design. Substitution in the RayleighRitz equation gives a first critical frequency of c g / y 9.81/ 7.624 108 11340 rad /s This represents a rotating speed of 108 000 rpm, which is an order of magnitude higher than the operating speed. Even accounting for deflection in the bearings, the critical speed will still be significantly higher than the design speed of the gearbox.This is not surprising given the stocky nature of the shaft with its small span. Deep groove ball bearings are proposed for the transmission as these bearings provide support for the radial load and axial alignment.The design life for the bearings is 1.02 108 revolutions.The maximum load on the bearings is approximately 310 N.The basic dynamic load rating required is given by 1.02 108 C 310 6 1 10
1/3

0.0121 m This length can readily be accommodated in the shaft and mating components. Because it is comparatively short, it would be possible to use the same type of key for the gears and couplings. This would have the advantage of a reduced parts inventory, simplifying tooling and economy of scale. An almost finished engineering drawing for the pinion shaft is given in Figure 16.11.The drawing includes the results of a considerable number of decisions. The calculations outlined so far in this case study have resulted in the specification of some of the major dimensions. However, geometric tolerances need to be specified on certain features in order to control features such as location, form, profile, orientation and runout, and ensure adequate assembly and operation of the machine. In addition, particular surface finishes must be specified on critical regions such as mating surfaces and areas experiencing reversed bending. A typical surface finish for a ground surface is 0.4 m and that for turning or milling is 1.6 m. Figure 16.11 should be examined by the reader and each dimension and feature scrutinized.

1448 N

A 30 mm bore bearing with a basic dynamic load rating greater than this value and a speed capability with grease filled bearings of more than 2850 rpm would be suitable.The bearings from a number of specialist bearing manufacturers should be considered. From Table 4.7, ISO designation

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0.10 174.60 0.10 0.10 173.10 0.10 0.10 149.00 0.10 0.10 113.00 0.10 0.10 100.00 0.10 0.10 98.00 0.10 0.10 76.50 0.10 0.10 36.50 0.10 R0.50 0.10 0.10 35.00 0.10 0.10 13.00 0.10
1.6

B
45

1.6

B
0.05 -A-

29.00 28.80

R0.50 0.10

30.028 30.017

A
0.05 -A39.042 39.026

0.03 -A-A30.028 30.017

0.03 -A0.05 -A38.06 38.00 45.00 45.06

R0.50 0.10 0.03 -A38.06 38.00

R0.22 R0.28
4.06 4.01

33.87 34.13

4.06 4.01

26.99 26.92

36.99 36.92

Section B-B

Section A-A

Figure 16.11 Pinion shaft.

The similarity in diameter required for the pinion shaft and gear shaft provides an opportunity to use a common design for both shafts.This has the advantage of reduced inventory, setting up costs

and economies of scale. This approach has been adopted for this design. The options for the transmission support and enclosure realistically include fabricating, moulding

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Figure 16.12 Casing.

Figure 16.13 General arrangement for the compressor transmission.

or casting using metal or plastic.The temperature of operation indicates that a plastic material is a possibility provided rigidity, strength and cost requirements are met. Metals are, however, an obvious choice. In order to provide rigid support use of a two-part casting assembly is explored in Figure 16.12.Turned inserts are proposed for the stationary bearing mountings. Although this solution appears adequate, fabrication and use of a plastic moulding should also be explored to identify whether they can meet the specification and provide a cost advantage. Engineering drawings, similar to that given in Figure 16.11, should also be produced for all the components in the transmission. Here, however, just a general arrangement for the overall transmission is given in Figure 16.13.

Although the design developed is probably far from optimal, an estimate of the works cost price should be developed in order to identify whether the proposal is likely to meet the specification in terms of price and which aspects are responsible for determining the majority of the costs.These can then be assessed and the use of expensive features justified or, if possible, removed from the design altogether. Estimating the cost of a product at the design stage is notoriously difficult. In the design proposal presented here, estimates for the costs of stock items such as the gears, bearings, keys and fasteners can be obtained by examination of price lists if published or by contacting the OEM or stock supplier concerned and obtaining a quotation. Ensure that the quotation provides the appropriate discount for the quantities concerned. For a production run of 1000 units per year, it is likely that the transmissions will be manufactured in batches. In this case a quotation for the necessary batch size would seem appropriate so that variations in demand will not tie up company capital unnecessarily. Estimates for the cost of the castings will need to be obtained by means of quotations from casting companies. In this design, machining of the shafts and finish machining of the castings needs to be performed either in-house or bought in. Obviously quotations from machine shops can be obtained to evaluate the possibility of buying the shafts directly. For in-house machining, reliance needs to be placed on experience or use of standard estimates for machining times. Standard estimates for a wide range of machining processes are outlined in Swift and Booker (1997). From Table 16.10, taking the materials overhead as 130 per cent and the labour overhead as 225 per cent, the works cost price is given by Works cost price (261 1.3) (156 2.25) 690.3 Euros The works cost price for the transmission system is close to the target price of 600 Euros. With careful control of procurement costs and inhouse manufacturing costs it should be possible to

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Table 16.10 Estimates for component costs based on a batch run of 100 gearboxes Item Pinion Gear Keys Shaft material Bearings Split rings Main casting Casting cover Casting seal Bearing mountings material Shaft seals Couplings Fasteners Gear hardening Materials subtotal Key way machining Turning Grinding Casting machining Bearing mountings machining Assembly Packaging Labour subtotal Number 1 off 1 off 6 off 2 off 4 off 2 off 1 off 1 off 1 off 4 off 2 off 2 off 20 off Batch of 200 6 off 2 off 2 off 1 off 4 off 1 off 1 off 2 min each 15 min/shaft 10 min/shaft 30 min 10 min/mounting 30 min 4 min Time Unit cost (Euro) 12 18 0.5 10 10 2 60 20 2 5 8 20 0.25 100 60/h 60/h 60/h 60/h 60/h 40/h 4 Total cost (Euro) 12 18 3 20 40 4 60 20 2 20 16 40 5 1 per transmission 261 12 30 20 30 40 20 4 156 Source of estimate Stock gear manufacturer Stock gear manufacturer Stock supplier Metal supplier Stock supplier Stock supplier Quotation from casting specialist Quotation from casting specialist O ring cording supplier Stock supplier Seal manufacturer Coupling manufacturer Fastener stock supplier Specialist service Machine shop In-house estimate In-house estimate In-house estimate In-house estimate In-house estimate In-house estimate

get this total cost well below the 600 Euro target.As such, the design is likely to meet the specification. A proposal for the compressor transmission has been developed. The design appears adequate in terms of function and compliance with the specification, although the works cost price has exceeded the target. It should, however, be possible to refine the design of the shaft and casing and bearing mounts to reduce costs and cheaper quotations for the stock items may be available. It is also possible that one of the alternative concepts, such as the belt drive, could be considerably cheaper to produce.

16.6 Conclusions
The design process can be modelled by the total design model comprising marketing, specification, conceptual design, detailed design, manufacturing and sales activities. Design is an iterative process involving repetition of activities and simultaneous

consideration of other phases.This book has outlined the total design process highlighting the importance of each area. Design skills have been encouraged in the areas of specification, concept generation, design assessment and detailed design. Specific to the detailed design activity, skills in the design, selection and specification of bearings, shafts, gears, belts, chains, clutches and brakes, springs and fasteners have been developed. Design is a fulfilling profession allowing the design and creation of new and better products. It is hoped that the information presented here will encourage you to apply and develop your design skills. References and sources of information
Books and papers Corbett, J. (1989). Manufacturing Phase. SEED, Sharing Experience in Engineering Design.