1

UNIVERSITI TENAGA NASIONAL
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
MEMD314 - MACHINE DESIGN

SEMESTER 1 2018/2019
PROJECT TITLE
DESIGN OF TURBINE GEAR-BOX
NAME STUDENT ID
MUHAMMAD AIMAN BIN MOHD MUTAZAR DM95137
AHMAD SYAHMI BIN TAJARAZHAR DM95037
SECTION : 01TB
LECTURER : MOHD RASHDAN BIN ISA
Due Date Submitted Date
30/8/2018 30/8/2018
[DESIGN OF TURBINE GEAR-BOX] MEMD 314
ABSTRACT
As the title, ‘Design of Turbine Gear-Box’, implies, this project requires us to analysis
and design a turbine gear box. To design the gear box, we have to follow the specifications that
have been determined for this project such as safety factor and reliability while considering
other properties such as weight, size, and design life.
Calculations and experiments involved throughout the completion of this project are
very important because they determine the value of the gearbox towards competing on the
current or local market value. The durability and the usability of the gearbox show the identity
of the gearbox compared to others in the market.
The calculations are made with the same reason which is to get the required yield and
fatigue safety factors. The main task is for us to go through different calculations to get the best
condition for the gearbox in terms of materials and cost. Days of research that we have to go
through not just to complete this project but to complete the gearbox with the best design.
At the end of this project, we finally came out with the most desirable gearbox based on
our assumption on the material and the calculation parts. Throughout the project, we had learnt
lot of things related to our subject, Machine Design(MEMD314). Besides that, we also learn to
develop teamwork, research skills, and creative thinking.
The design of the turbine gear box is that we are proposing satisfies all the required
values and the selection of the materials and cost involved makes our design more efficient and
desirable for it to function in a best condition in a turbine system.
1
TABLE OF CONTENT`
Content Page
1.0 Introduction 3
1.1 Background 3
1.2 Function of product 4
1.3 Advantage and Disadvantage 4
2.0 Project Title 5
3.0 Project Objective 5
4.0 Design 5
4.1 Detail Drawing 5-7
4.2 3D Model 8-11
5.0 Specification 12
6.0 Calculation of Parts 13

6.1 Calculation of Gear 13-24
6.2 Calculation of Shaft 24-29
6.3 Calculation of Bearing 30-31
6.4 Calculation of Key 32-35
7.0 Mass and Costs 36
8.0 Discussion and Conclusion 37
9.0 Reference 38
2
1.0 INTRODUCTION
1.1 Background
A turbine is basically a rotary mechanical device that gains energy from a fluid flow and
then converts it into a useful work. This machine consists of shafts that create the rotational
movement of the blades. Examples of turbine are turbofan engine on commercial aircraft and
windmill.
When it comes to gearing components, things can get confusing quickly. There are
many terms that gear manufacturers as well as engineers and designers use to talk about what
sometimes is essentially the same thing. And the term “gearbox” is one of those terms, often
times used interchangeably with gearhead or gear reducer, even though they may in fact refer
to slightly different physical arrangements of gears.
The most basic definition of a gearbox is that it is a contained gear train, or a mechanical
unit or component consisting of a series of integrated gears within a housing. In fact, the name
itself defines what it is; a box containing gears. In the most basic sense, a gearbox functions
like any system of gears; it alters torque and speed between a driving device like a motor and a
load.
The gear box has to be designed in the most efficient way. We select a rectangular
configuration for the gear box, with the usage of 2 gears and also 2 shafts. The minimum safety
factors required for the gears are 1.2 for surface failure and 1.5 for bending failure. The shafts
and the bearings need to meet a minimum safety factor of 2.0. However, for the keys, a
minimum yield safety factor of 1.5 is needed. This will make certain the keys will fail first in
the design before any other parts. The specifications determined have to be followed to achieve
the best and reliable design of the gearbox.
3
In the calculation part, we took the value of gear quality numbers, Qv based on the
application on aircraft engine drive from the ‘Recommended AGMA Gear Quality Numbers
for Various Applications’ table.
1.2 Function of Product
Our function of design gearboxes are used to increase torque while reducing the speed of a
prime mover output shaft (e.g. a motor crankshaft). This means that the output shaft of a gearbox
rotates at a slower rate than the input shaft, and this reduction in speed produces a mechanical
advantage, increasing torque. A gearbox can be set up to do the opposite and provide an increase
in shaft speed with a reduction of torque. Some of the simplest gearboxes merely change the
physical rotational direction of power transmission.
Our design gearboxes also have function in a wide variety of different often stationary
applications, such as like wind turbines. The general reason for using gears is that different
parts need to run at different speeds for efficiency. In order for a compact electrical generator
to work well, some parts have to move fairly fast, since the voltages generated depend on how
fast some magnetic fields are changing. The turbine blades themselves, however, can't turn very
fast because they wouldn't be able to take the centrifugal strain. So a gear box is needed to step
up the slow turbine motion rotations to the faster generator rotations. One alternative to using
gearboxes, however, is to use a larger generator with permanent magnets.
1.3 Advantage and Disadvantage
 For the disadvantage, the precise amount of gearing needed depends on various factors
including the wind speed, so in most turbines the gears can be shifted, like those in a
car.
 For the advantage this designs which use fixed mechanical gears and instead electrically
switch the connections of some of the coils in the generator, changing its optimal
operating speed. Electrical switches are faster and easier to control than are mechanical
gear shifters, so this should improve turbine performance. Also, it can reducing overall
size, weight, and cost. In some cases, the number of bearings can be reduced in the
4
drivetrain. The gearbox would consist of just one or two planetary gear stages with no
high-speed shaft. The concern with this design is that when failures occur, both units
gearbox and generator.
2.0 PROJECT TITLE
Design of Turbine Gear-Box.
3.0 PROJECT OBJECTIVE
The objective of the project is to student design a turbine gear-box which consists of spur gears,
rolling element bearings, shafts, keys or press fits, seals and housing. Furthermore, this project
objective to helps us to gain more knowledge on the gear box especially on the calculation part
besides other properties to be chosen to achieve the most desirable gear box design. Also, when
the safety factor is too low, the mechanism will reach failure and break. Thus, in order to
achieve a successful designing of mechanism, the mechanism must have a safety factor of 1 or
higher than 1
4.0 DESIGN
Project Drawing:
4.1 Detail Drawing
5
Diagram 1: Spur Gear
Diagram 2: Bearing
6
Diagram 3: Key
7
4.2 3D Model
Diagram 1: Spur Gear
Diagram 2: Input Shaft
8
Diagram 3: Output Shaft
Diagram 4: Pinion 1
9
Diagram 5: Outside view of the Table Saw Gear Box
10
Diagram 6: Bearing, Spur Gear and Key
Diagram 7: Gearbox in Windmill turbine
11
5.0 SPECIFICATIONS
Gear box specifications:
Weight : Minimal and compact

Size : Minimal and compact
Design life : 10 years in continuous operation
Weak link design : Design the input shaft key or output shaft key to a yield factor of
safety about 1.5
Predetermine value:
Keys : R=90% Minimum FSf = 2.0, FSy = 2.0
Shafts : R=90% FS =2.0
Bearings : R=99% FS=1.0
Bearings check : Static failure, Co using full load conditions, FS =2.0
Design gears : R=90% FSf = 1.2 surface, 1.5 bending
Other parts : R=90% FSf = 2.0, FSy = 2.0
12
6.0 CALCULATION OF PARTS
6.1 Calculation of gear
Motor input = 300k watts

Output speed (output shaft rotation) = 2950rpm
Assumptions:
1. The design of the gear box is to increase the speed from the input rpm. We increase it by
3.612 from the input rpm.
Therefore, the input speed is:-
2950 rpm / 3.612 = 816.5 rpm
The gear ratio is 1: 3.612
2. Input gear:-
 Diameter = 5 in
 Thickness = 1.5 in
 Ng = 135 teeth
3. Output gear (pinion):-

 Diameter = 2 in
 Thickness = 1.5 in
 Np = Ng/3.612
= 37 teeth
13
Gear tooth specifications:

Pd = 6
Therefore, coarse pitch (Pd < 20)
Parameter Equation , Pd = 6 values

Addendum a 1.000/Pd 0.167
Dedendum b 1.250/Pd 0.208
Working depth 2.000/Pd 0.333
Whole depth 2.250/Pd 0.375
Circular tooth thickness 1.571/Pd 0.262
Fillet radius-basic rack 0.300/Pd 0.050
Minimum basic clearance 0.250/Pd 0.042
Minimum width of top land 0.250/Pd 0.042
Clearance(shave or ground 0.350/Pd 0.058
teeth)
Table 1: Value of Pd for Each Parameter
Assumed pinion Np = 100, gear Ng = 36 , then the pitch diameter for that combinations is
𝑁𝑝 37
dp = = = 6.16 in
𝑃𝑑 6
𝑁𝑔 135
dg = = = 22.5 in
𝑃𝑑 6
6 is a standard pitch by referred from table 12-2, pg. 719 (Machine design textbook, 4th
Edition)
Torque:
P = Tω
P = 300k watts = 402.3 hp
14
6.1.1 Input Gear
(816.5 𝑟𝑝𝑚) 𝑥 2𝜋
ω = 816.5 rpm = = 85.50 rad/sec
60
T = P/ω
6600 𝑙𝑏.𝑖𝑛/𝑠𝑒𝑐
(402.3 ℎ𝑝)( )
ℎ𝑝
= = 31054.74 lb.in
85.50 𝑟𝑎𝑑/𝑠𝑒𝑐
Tmax = 31054.74 lb.in

Tmin = 0 lb.in
Ta = Tmax – Tmin / 2
= 15527.37 lb.in
Tm = Tmax + Tmin / 2
= 15527.37 lb.in
Wtmax = Tmax / rg
= 31054.74 lb.in /11.25 in
= 2760.42 lb
Wtmin = Tmin / rg
=0
Wta = 15527.37 lb in /11.25 in
= 1380.21 lb
Wtm = 15527.37 lb in /11.25 in

= 1380.21 lb
15
6.1.2 Output Gear (Pinion)
(2950 𝑟𝑝𝑚) 𝑥 2𝜋
ω = 2950 rpm = = 308.92 rad/sec
60
T = P/ω
6600 𝑙𝑏.𝑖𝑛/𝑠𝑒𝑐
(402.3 ℎ𝑝)( )
ℎ𝑝
= = 8595.04 lb.in
308.92 𝑟𝑎𝑑/𝑠𝑒𝑐
Tmax = 8595.04 lb.in

Tmin = 0
Ta = Tmax – Tmin / 2
= 4297.52 lb.in
Tm = Tmax + Tmin / 2
= 4297.52 lb.in
Wtmax = Tmax / rp
= 8595.04 lb.in /3.08 in
= 2790.59 lb
Wtmin = Tmin / rp
=0
Wta = 4297.52 lb.in / 3. 08 in
= 1395.29 lb
Wtm = 4297.52 lb.in / 3. 08 in
= 1395.29 lb
By taking the pressure angle as 25 ͦ and using the formula W = Wt / cos (25), to calculate the
forces that exist on each part of the system.
For gear part For pinion part
Wtmax = 2760.42 lb Wtmax = 2790.59 lb

Wtm = 1380.21 lb Wtm = 1395.29 lb
Wta =1380.21 lb Wta = 1395.29 lb
16
6.1.3 Overall Gear Calculation
For the gear calculation, there is only one part of calculation that is input gear-pinion output
since it is the single stage gear box.
Assumption:
1. The stresses that will be analyses are the bending stress and the surfaces stress.
2. The bending stress equation for stress:

𝑊𝑡.𝑃𝑑.𝐾𝑎.𝐾𝑚.𝐾𝑠.𝐾𝑎.𝐾𝑏.𝐾𝑖
𝜎b =
𝐹.𝐽.𝐾𝑣
a) Wt = 2760.42 lb
b) Pd = 6
c) Face width factor, F = 12/ Pd
=2
d) Assume AGMA Quality Factor is for aircraft engine drive, so Qv = 10
e) The dynamic load factor, Kv, B = ((12 – Qv) ^ (2/3) ) / 4 B = 0.397
A = 50+ 56(1-B) A = 83.768
f) Pitch-line Velocity, Vtg = (dg/2) *ωg
= (22.5/2*12) (816.5 rpm *2𝜋)
= 4809.58 ft/min
g) Pitch-line Velocity, Vtp = (dp/2) *ωg
= (6.16/2*12) (816.5 rpm *2𝜋)
= 4757.42 ft/min
𝐴
h) Velocity factor, Kvg = Cvg =[𝐴+√Vt𝑔] ^B
= 0.547^0.397
= 0.79
𝐴
i) Velocity factor, Kvp = Cvp =[𝐴+√Vtp] ^B
= 0.547^0.397
= 0.79
17
j) Mounting Factor,
(assume) F, Face width <= 2
Km =1.6 (Refer to Table 12-16)
Ka = 1.0 (due to uniform load) (Refer to Table 12-17)
k) Assume bending geometry factor, J for 25ᵒ, full depth teeth with HPSTC loading:
Jg = 0.543
Jp = 0.4875
l) Taking/assume: -
Ks = 1
Kb = 1
KI =1
m) The bending stress for pinion and gear:
𝑊𝑡.𝑃𝑑.𝐾𝑎.𝐾𝑚.𝐾𝑠.𝐾𝑎.𝐾𝑖
𝜎bg =
𝐹.𝐽.𝐾𝑣
(2760.42∗6∗1∗1.6∗1∗1∗1)
=
2∗0.543∗0.79
= 30887.9 psi
= 0.03088 Mpsi
𝑊𝑡.𝑃𝑑.𝐾𝑎.𝐾𝑚.𝐾𝑠.𝐾𝑎.𝐾𝑏
𝜎bp =
𝐹.𝐽.𝐾𝑣
(𝟐𝟕𝟗𝟎.𝟓𝟗 ∗6∗1∗1.6∗1∗1∗1)
=
2∗0.4875∗0.79
= 34780.48 psi
= 0.035M psi
18
3. Surface Stress:
a) The surface stress for pinion-gear: - (assume the material for the pinion and gear made of
steel so Ep = Eg = 30E6 psi)( Vp = Vp = 0.28 )(from table 12-18)
Elastic coefficient for steel, Cp = 2276 (From equation 12.23)
Surface factor, Cf = 1 (Well finished gear by conventional method)
b) The surface geometry factor I can be calculated:
Gear (Idle)
ρ1 = ((rg + (1/Pd)² - (rg cos ∅ )²) ^ (1/2) – ((𝜋/Pd)*cos∅)
= [(11.25) + (1/6)) ² - (11.25 cos 25) ²] ^ 0.5 – [(𝜋/6)* cos 25]
= 4.7
ρ2 = C sin ∅ - ρ1
= (rp + rg) sin ∅ - ρ1
= (3.08 + 11.25) sin 25 – 4.7
= 1.42
I = (cos ∅)/((1/𝜌1 + 1/ρ2)* dg)
= (cos 25) / ((1/4.7 + 1/1.42)*22.5)
= 0.045
c) Surface stress in pinion-gear mesh:
Assume Ca,Cm,Cv,Cs are equal respectively to Ka,Km,Kv,Ks as define for the bending
stress equation.
Assume Cf = 1 as the gear and pinion are made by conventional method
𝑊𝑡.𝐶𝑎.𝐶𝑚.𝐶𝑠.𝐶𝑓 1
𝜎cig = 𝐶𝑝( )^( )
𝐹.𝑑𝑔.𝐶𝑣.𝐼 2
= 2276[(2760.42*1*1.6*1*1) / ( 2 ∗ 22.5 ∗ 0.79 ∗ 0.045)]^(1/2)

= 119589.69 psi
= 0.119 Mpsi
Pinion (Idle)
ρ1 = ((rp + (1/Pd)² - (rp cos ∅ )²) ^ (1/2) – ((𝜋/Pd)*cos∅)
19
= [(3.08) + (1/6)) ² - (3.08 cos 25) ²] ^ 0.5 – [(𝜋/6)* cos 25]

= 1.183
ρ2 = C sin ∅ - ρ1
= (rp + rg) sin ∅ - ρ1
= (3.08 + 11.25) sin 25 – 1.183
= 4.87
I = (cos ∅)/((1/𝜌1 + 1/ρ2)* dp)
= (cos 25) / ((1/1.183 + 1/4.87)*6.16)
= 0.14
d) Surface stress in pinion-gear mesh:

assume Ca,Cm,Cv,Cs are equal respectively to Ka,Km,Kv,Ks as define for the bending sterss
equation.
assume Cf = 1 as the gear and pinion are made by conventional method
𝑊𝑡.𝐶𝑎.𝐶𝑚.𝐶𝑠.𝐶𝑓 1
𝜎cip = 𝐶𝑝( )^( )
𝐹.𝑑𝑝.𝐶𝑣.𝐼 2
= 2276[(2790.59 *1*1.6*1*1) / ( 2 ∗ 6.16 ∗ 0.79 ∗ 0.14)]^(1/2)

= 130285.87 psi
= 0.130 Mpsi
4. Calculate corrected bending fatigue strength:

 For gear
20
i) assume using AGMA class A4 steel, through hardened to 350HB

The uncorrected bending fatigue strength: -
Sfb’ = 6235 + 174HB - 0.126HB2 ----- (using grade 2 maximum)
= 6235 + 174(350) - 0.126(350)2
= 51700 psi
= 0.0517 Mpsi
ii) Number of cycles:-
Assume 10 year life in continuous operation.
N = (2950rpm)(60 min/hr)(8760hr/yr) (10 year)
= 1.55E10 cycles
iii) The value of KL
KL = 1.6831(1.55E10) ^ (-0.0323)
= 0.789
iv) Operate at specified temperature
Kt = 1
v) Realibility =90%
Kr = 0.85
vi) Corrected surface fatigue strength:-
Sfb = (KL /( Kt *Kr)) * Sfb’
= 0.047989 Mpsi
 For pinion
i) assume using AGMA class A5 steel, through hardened to 400HB

The uncorrected bending fatigue strength: -
Sfb’ = 6235 + 174HB - 0.126HB2 ----- (using grade 2 maximum)
= 6235 + 174(400) - 0.126(400)2
= 55675 psi
= 0.056 Mpsi
ii) Number of cycles:
21
Assume 10 year life in continuous operation.

N = (2950rpm)(60 min/hr)(8760hr/yr) (10 year)
= 1.55E10 cycles
iii) The value of KL
KL = 1.6831(1.55E10) ^ (-0.0323)
= 0.789
iv) Operate at specified temperature
Kt = 1
v) Realibility =90%
Kr = 0.85
vi) Corrected surface fatigue strength:-
Sfb = (KL /( Kt *Kr)) * Sfb’
= 0.05198 Mpsi
5. Calculate corrected surface fatigue strength:

 For gear :-
i) For an AGMA A4 steel, through hardened to 360 HB

Sfc’ = 27000 + 364HB ---- (using grade 2 maximum)
= 27000 + 364(360)
= 158040 psi
= 0.158 Mpsi
ii) CL =2.466 (1.55E10) ^ (-0.056)
= 0.663
iii) Ct =Kt=1
iv) Cr=Kr=0.85
v) CH = 1 (assume gear and pinion of the same hardness material)
vi) The corrected surface fatigue strength:
22
Sfc = ((CL.CH )/(CT.Cr))* Sfc’

= [ 0.663x1/(1x0.85)] * 0.158 Mpsi
= 0.123 Mpsi
 For pinion :-
i) For an AGMA A5 steel, through hardened to 400 HB

Sfc’ = 27000 + 364HB ---- (using grade 2 maximum)
= 27000 + 364(400)
= 172600 psi
= 0.173 Mpsi
ii) CL =2.466 (1.55E10) ^ (-0.056)
= 0.663
iii) Ct =Kt=1
iv) Cr=Kr=0.85
v) CH = 1 (assume gear and pinion of the same hardness material)
vi) The corrected surface fatigue strength:
Sfc = ((CL.CH )/(CT.Cr))* Sfc’

= [ 0.663x1/(1x0.85)] * 0.173 Mpsi
= 0.1382 Mpsi
6. Factor of safety for gear, pinion and surface gear-pinion:
i) FSgear = Sfb / 𝜎 bg
= 0.047989 Mpsi / 0.03088 Mpsi

Nb gear = 1.55
ii) FSpinion = Sfb / 𝜎 bp

= 0.051981Mpsi / 0.034780M psi
Nb pinion = 1.5
23
iii) FSidler-gear = (Sfc / 𝜎 ci-g)²
= (0.123 Mpsi/ 0.119 Mpsi)²

Nc idler-gear = 1.1
iv) FSidler-pinion = (Sfc / 𝜎 ci-p)²

= (0.1382 Mpsi/ 0.130285 Mpsi)²
Nc idler-gear = 1.13
6.2 Calculation of Shaft
In this shaft analysis, got 2 shafts needed to be analysis which are input shaft and the output
shaft.
In the same time, we assume that both shafts using the same material thus they will have the
same Ultimate tensile strength (Sut) and yield strength (Sy).
We use SAE 1018 Cold-Rolled Steel because it inexpensize, low-carbon, cold-rolled steel
Sut = 64 kpsi
Sy = 54 kpsi
Uncorrected fatigue strength Steels

Se’= 0.5Sut
= 0.5(64000)
= 32000 kpsi
(Refer to book of Machine Design, 4th Edition by Robert L. Norton, Chapter 6.6)
Load : Cload = 1 (bending load)
Size : Csize = 1
Surface : Refer Table 6-3: A = 2.7
b = -0.265 (machined cold
rolled)
Csurface = A. (Sut)b = 2.7 ( 64 )-0.265 = 0.84
Temperature : Ctemp = 1
24
Realibility : Creliab = 0.897 (R = 90 %) Refer Table 6-4
Modified Endurance Limit:

Sf = Cload . Csize . Csurf . Ctemp . Creliab . Sf’
= 24111.36 kpsi
6.2.1 Analysis of Input Shaft
1. Maximum and minimum force at input shaft

𝑇𝑚𝑎𝑥
𝐹𝑡𝑚𝑎𝑥 =
𝑟𝑔
Where 𝑇𝑚𝑎𝑥 is the maximum torque exert on the input shaft through gear which gives
𝐹𝑡𝑚𝑎𝑥 = 186.434 lb
Where, minimum force at input shaft is 0 lb because the minimum force is 0.
2. Maximum and minimum resultant force

𝐹𝑡𝑚𝑎𝑥 186.434
𝐹𝑚𝑎𝑥 = =
cos ∅ cos(20)
Where 𝐹𝑡𝑚𝑎𝑥 is taken from last calculation gives 𝐹𝑚𝑎𝑥 = 198.399 lb
3. Maximum and minimum moment

Assume gears will centered between the simply supported bearings set 4 in apart. Therefore,
length of shaft is 4 in.
𝑙 𝑥 𝐹𝑚𝑎𝑥
𝑀𝑚𝑎𝑥 =
4
(4 𝑥 198.399 )
𝑀𝑚𝑎𝑥 = = 198.399 𝑙𝑏. 𝑖𝑛
4
Where minimum moment is zero because 𝐹𝑚𝑖𝑛 is 0.
25
4. Finding 𝑀𝑚𝑒𝑎𝑛 and 𝑀𝑎𝑙𝑡𝑒𝑟𝑛𝑎𝑡𝑖𝑛𝑔

𝑀𝑚𝑎𝑥 + 𝑀𝑚𝑖𝑛
𝑀𝑚 =
2
𝑀𝑚𝑎𝑥 − 𝑀𝑚𝑖𝑛
𝑀𝑎 =
2
198.399 − 0
𝑀𝑚 = 𝑀𝑎 =
2
𝑀𝑚 = 𝑀𝑎 = 99.1995 𝑙𝑏. 𝑖𝑛
5. Finding 𝑇𝑚 and 𝑇𝑎
𝑇𝑚𝑎𝑥 + 𝑇𝑚𝑖𝑛
𝑇𝑚 =
2
𝑇𝑚𝑎𝑥 − 𝑇𝑚𝑖𝑛
𝑇𝑎 =
2
186.434 − 0
𝑇𝑎 = 𝑇𝑚 =
2
𝑇𝑎 = 𝑇𝑚 = 93.217 𝑙𝑏. 𝑖𝑛
6. Calculating uncorrected endurance strength, 𝑆è

𝑆è = 0.5𝑆𝑢𝑡
𝑆è = 0.5(64000)
𝑆è = 32000 𝑝𝑠𝑖
Where the material used is SAE 1018 cold-rolled steel with 𝑆𝑢𝑡 = 64 kpsi and 𝑆𝑦 = 54 kpsi
gives 𝑆è = 32000 𝑝𝑠𝑖
𝑆𝑒 = 𝐶𝑙𝑜𝑎𝑑 𝐶𝑠𝑖𝑧𝑒 𝐶𝑠𝑢𝑟𝑓 𝐶𝑡𝑒𝑚𝑝 𝐶𝑟𝑒𝑙𝑖𝑎𝑏 𝑆è
Where: - 𝐶𝑙𝑜𝑎𝑑 = 1 𝑓𝑜𝑟 𝑏𝑒𝑛𝑑𝑖𝑛𝑔 𝑎𝑛𝑑 𝑡𝑜𝑟𝑠𝑖𝑜𝑛, 𝐶𝑠𝑖𝑧𝑒 =
1 𝑠𝑖𝑛𝑐𝑒 𝑤𝑒 𝑑𝑜𝑛𝑡 𝑘𝑛𝑜𝑤 𝑡ℎ𝑒 𝑠𝑖𝑧𝑒
𝐶𝑠𝑢𝑟𝑓 = 0.84, 𝐶𝑡𝑒𝑚𝑝 = 1 𝑠𝑖𝑛𝑐𝑒 𝑛𝑜 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑔𝑖𝑣𝑒𝑛,
𝐶𝑟𝑒𝑙𝑖𝑎𝑏 = 0.897 𝑓𝑜𝑟 90% 𝑟𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦.
𝑆𝑒 = (1)(1)(0.84)(1)(0.897)(32000)
𝑆𝑒 = 24111.36 𝑝𝑠𝑖
26
7. Finding bending and torsional stress in the keyway

𝐾𝑓 = 1 + 𝑞(𝐾𝑡 − 1)
Where notch sensitivity of the material is found from Figure 6-36 and for bending is q = 0.50,
and for torsion q = 0.57 for assumed notch radius of 0.01in.
Therefore it will gives
𝐾𝑓 = 1 + 𝑞(𝐾𝑡 − 1)
𝐾𝑓 = 1 + 0.5(3.0 − 1)
𝐾𝑓 = 𝐾𝑓𝑚 = 2.00
𝐾𝑓 = 1 + 𝑞(𝐾𝑡 − 1)
𝐾𝑓 = 1 + 0.57(3.0 − 1)
𝐾𝑓𝑠 = 𝐾𝑓𝑠𝑚 = 2.15
8. Finding input diameter

Assume 𝑁𝑠𝑓 = 2.5
1
3
2 3 2 3 2
32𝑁𝑠𝑓 √((𝑘𝑓 𝑀𝑎 ) + (𝑘𝑓𝑠 𝑇𝑎 )2 √(𝑘𝑓𝑚 𝑀𝑚 ) + (𝑘𝑓𝑠𝑚 𝑇𝑚 )
4 4
𝑑𝑖𝑛𝑝𝑢𝑡 = +
𝜋 𝑆𝑓 𝑆𝑢𝑡
( )
( )
2 3 2
32(2.5) √((2)(99.1995)) + 4 ((2.15)(93.217))
𝑑𝑖𝑛𝑝𝑢𝑡 =
𝜋 24111.36
(
(
1
3
2 3
√((2)(99.1995))) + ((2.15)(93.217))2
4
+
64000
)
)
𝑑𝑖𝑛𝑝𝑢𝑡 = 0.6872 in
27
6.2.2 Analysis of Output Shaft
1. The output shaft has the same mean and alternating bending moments as the input shaft, but
its torque is only 40 % of the output shafts. The mean and alternating torques on it are :
𝑇𝑚𝑎𝑥 + 𝑇𝑚𝑖𝑛
𝑇𝑚 =
2
𝑇𝑚𝑎𝑥 − 𝑇𝑚𝑖𝑛
𝑇𝑎 =
2
186.434 − 0
𝑇𝑎 = 𝑇𝑚 =
2
𝑇𝑎 = 𝑇𝑚 = 93.217 𝑙𝑏. 𝑖𝑛 x 40% = 37.2868 𝑙𝑏. 𝑖𝑛
2. Finding output diameter
1
3
2 3 2 3 2
32𝑁𝑠𝑓 √((𝑘𝑓 𝑀𝑎 ) + (𝑘𝑓𝑠 𝑇𝑎 )2 √(𝑘𝑓𝑚 𝑀𝑚 ) + (𝑘𝑓𝑠𝑚 𝑇𝑚 )
4 4
𝑑𝑜𝑢𝑡𝑝𝑢𝑡 = +
𝜋 𝑆𝑓 𝑆𝑢𝑡
( )
( )
2 3 2
32(2.5) √((2)(99.1995 )) + 4 ((2.15)(37.2868))
𝑑𝑜𝑢𝑡𝑝𝑢𝑡 =
𝜋 24111.36
(
(
1
3
2 3
√((2)(99.1995)) + ((2.15)(37.2868))2
4
+
64000
)
)
𝑑𝑜𝑢𝑡𝑝𝑢𝑡 = 0.6105 in
28
6.2.3 Analysis of Shaft Deflection
1. Input shaft (deflection)
Angular deflection in ∅ (radian)

𝑇𝑙
∅=
𝐺𝐽
𝜋𝑑4 𝜋(0.6872)4
Where, J for solid shaft is J = = = 0.0219 𝑖𝑛4
32 32
𝑙= length of shaft
T= torque experience at shaft
G for steel carbon = 11.7Mpsi
Therefore,
(93.217)(4)
𝜃=
(0.0219)(11.7M)
𝜃 = 1.455 𝑥10−3 𝑖𝑛4
6.3.3.2 Output shaft (deflection)
𝜋𝑑4 𝜋(0.6105)4
Where, J for solid shaft is J = = = 0.0136 𝑖𝑛4
32 32
(37.2868)(4)
𝜃=
(0.0136)(11.7M)
𝜃 = 9.373 𝑥10−4 𝑖𝑛
29
6.3 Calculation of Bearing
1. Input bearing:
𝑑𝑠ℎ𝑎𝑓𝑡 = 0.6872 𝑖𝑛
𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑛𝑢𝑚𝑏𝑒𝑟 = 6304
𝐶 = 3000 𝑙𝑏
𝐶𝑜 = 1930 𝑙𝑏
𝑇 186.434
𝑃 = = = 46.6085 𝑙𝑏
𝐿𝑠ℎ𝑎𝑓𝑡 4
𝐾𝑅 = 0.21 (𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 99% )
𝐶𝑜 3 1930 3
𝐿10 = ( ) = ( ) = 71.003𝑥103 𝑐𝑦𝑐𝑙𝑒𝑠
𝑃 46.6085
𝐿𝑃 = 𝐾𝑅 𝐿10 = 0.21 (71.003𝑥103 ) = 14.911𝑥103 𝑐𝑦𝑐𝑙𝑒𝑠
Assumed
l/d = 0.75
So bearing length, l = 0.75(0.6872 in)
= 0.5154 in
Refer Figure 11-23(Textbook Machine Design 4th Edition pg. 688)

Bearing number 6304
Bore/Internal diameter = 0.7874 in
Outer diameter = 2.0472 in
Width = 0.5906 in
30
2. Output bearing:
𝑑𝑠ℎ𝑎𝑓𝑡 = 0.6105 𝑖𝑛
𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑛𝑢𝑚𝑏𝑒𝑟 = 6303
𝐶 = 2320 𝑙𝑏
𝐶𝑜 = 1460 𝑙𝑏
𝑇 93.217
𝑃 = = = 23.3043 𝑙𝑏
𝐿𝑠ℎ𝑎𝑓𝑡 4
𝐾𝑅 = 0.21 (𝑅𝑒𝑙𝑖𝑎𝑏𝑖𝑙𝑖𝑡𝑦 99% )
𝐶𝑜 3 1460 3
𝐿10 = ( ) = ( ) = 2.459𝑥105 𝑐𝑦𝑐𝑙𝑒𝑠
𝑃 23.3043
𝐿𝑃 = 𝐾𝑅 𝐿10 = 0.21 (2.459𝑥105 ) = 5.164𝑥104 𝑐𝑦𝑐𝑙𝑒𝑠
Assumed
l/d = 0.75
So bearing length, l = 0.75(0.6105 in)
= 0.4579 in
Refer Figure 11-23(Textbook Machine Design 4th Edition pg. 688)

Bearing number 6303
Bore/Internal diameter = 0.6693 in
Outer diameter = 1.8504 in
Width = 0.5118 in
31
6.4 Calculation of Key
1. 1st Shaft (gear shaft)
Mean torque = 93.217 lb. in Diameter = 0.6872 in

Alternating torque = 93.217 lb. in
𝑇𝑎 93.217
Fm = 𝐹𝑎 = = = 271.295 𝑙𝑏
𝑟 0.3436
Assumption X inch of the alternating and mean shear stress components

Based on Table 10-2 (Textbook). Assumed key length = 0.5 in:
𝐹𝑎 271.295
𝜏𝑎 = = (0.187)(0.5) =2901.55 psi
𝐴 𝑠ℎ𝑒𝑎𝑟
𝐹𝑚 271.295
𝜏𝑚 = = = 2901.55 𝑝𝑠𝑖
𝐴 𝑠ℎ𝑒𝑎𝑟 (0.187)(0.5)
Von Mises equivalent stresses for each component:
𝜎 ′ 𝑎 = √𝜎𝑥 2 + 𝜎𝑦 2 − 𝜎𝑥 2 𝜎𝑦 2 + 3𝜏 2 𝑥𝑦 = √3(2901.55 )² = 4103.411 𝑝𝑠𝑖
𝜎 ′ 𝑚 = √𝜎𝑥 2 + 𝜎𝑦 2 − 𝜎𝑥 2 𝜎𝑦 2 + 3𝜏 2 𝑥𝑦 = √3(2901.55 )² = 4103.411 𝑝𝑠𝑖
From this we achieved the fatigue safety factor:

1 1
Nf = 𝜎′𝑎 𝜎′𝑚 = 4103.411 4103.411 = 4.268
+ +
𝑆𝑒 𝑆𝑢𝑡 24111.36 64000
32
Maximum force of the key

𝐹𝑚 + 𝐹𝑎 271.295 + 271.295
𝜎 ′ 𝑚𝑎𝑥 = = = 8681.44 𝑝𝑠𝑖
𝐴 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 0.125(0.5)
Safety factor for bearing failure

𝑆𝑦 54000
𝑁𝑠 = = = 6.22
𝜎𝑚𝑎𝑥 8681.44
All the assumption is for worst case scenario. To find the safety factor, first, we must find the
𝑟⁄𝑑 ratios for this certain point and get the value of Kt, Kts, from Figure 10-16. We assumed a
radius on the end mill is 0.010 inch.
𝑟 0.010
= = 0.0146
𝑑 0.6872
Kt = 2.5
Kts = 2.7
1
𝐾𝑓 = 1 + 𝑞(𝐾𝑡 − 1) ; Where 𝑞 = = 0.5 (bending)
√𝑎
1+
√𝑟
Kf = 1.75
𝐾𝑓𝑠 = 1 + 𝑞(𝐾𝑡𝑠 − 1)
𝐾𝑓𝑠 = 1 + 0.5(2.7 − 1) = 1.85
𝐾𝑓𝑠𝑚 = 𝐾𝑓𝑠 =1.85
1/3
2 2 1/2
32𝑁𝑓 𝑀𝑎 3 𝑇𝑚
𝑑1 = { [(𝐾𝑓 ) + (𝐾𝑓𝑠𝑚 ) ] }
𝜋 𝑆𝑓 4 𝑆𝑦
𝑁𝑓 = 4.13
33
2. 2nd Shaft (pinion shaft)
Mean torque = 37.287 lb. in Diameter = 0.6105 inch

Alternating torque = 37.287 lb. in
𝑇𝑎 37.287
𝐹𝑎 = = = 122.152 𝑙𝑏
𝑟 0.30525
𝑇𝑚 37.287
𝐹𝑚 = = = 122.152 𝑙𝑏
𝑟 0.30525
Assumption X inch of the alternating and mean shear stress components

Assumed key length 0.5 = inch:
𝐹𝑎 122.152
𝜏𝑎 = = (0.187)(0.5) =1306.439 psi
𝐴 𝑠ℎ𝑒𝑎𝑟
𝐹𝑚 122.152
𝜏𝑚 = = = 1306.439 𝑝𝑠𝑖
𝐴 𝑠ℎ𝑒𝑎𝑟 (0.187)(0.5)
Von Mises equivalent stresses for each component;
𝜎 ′ 𝑎 = √𝜎𝑥 2 + 𝜎𝑦 2 − 𝜎𝑥 2 𝜎𝑦 2 + 3𝜏 2 𝑥𝑦 = √3(1306.439 )² = 2262.819 𝑝𝑠𝑖
𝜎 ′ 𝑚 = √𝜎𝑥 2 + 𝜎𝑦 2 − 𝜎𝑥 2 𝜎𝑦 2 + 3𝜏 2 𝑥𝑦 = √3(1306.439 )² = 2262.819 𝑝𝑠𝑖
From this we achieved the fatigue safety factor:

1 1
Nf = 𝜎′𝑎 𝜎′𝑚 = 2262.819 2262.819 = 7.74
+ +
𝑆𝑒 𝑆𝑢𝑡 24111.36 64000
34
Maximum force of the key

𝐹𝑚 + 𝐹𝑎 122.152 + 122.152
𝜎𝑚𝑎𝑥 = = = 3908.864 𝑝𝑠𝑖
𝐴 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 (0.125)(0.5)
Safety factor for bearing failure
𝑆𝑦 54000
𝑁𝑠 = = = 13.815
𝜎𝑚𝑎𝑥 3908.864
All the assumption are for worst case scenario. To find the safety factor, we first must find the
𝑟⁄𝑑 ratios for this certain point and get the value of Kt , Kts ,from Figure 10-16. We assumed a
radius on the end mill is 0.010 inch.
𝑟 0.010
= = 0.016
𝑑 0.6105
Kt = 2.35
Kts = 2.75
1
𝐾𝑓 = 1 + 𝑞(𝐾𝑡 − 1) ; Where 𝑞 = √𝑎
= 0.5 (bending)
1+
√𝑟
Kf = 1.675
𝐾𝑓𝑠 = 1 + 𝑞(𝐾𝑡𝑠 − 1)
𝐾𝑓𝑠 = 1 + 0.5(2.75 − 1) = 1.875
𝐾𝑓𝑠𝑚 = 𝐾𝑓𝑠 =1.875
1/3
2 2 1/2
32𝑁𝑓 𝑀𝑎 3 𝑇𝑚
𝑑2 = { [(𝐾𝑓 ) + (𝐾𝑓𝑠𝑚 ) ] }
𝜋 𝑆𝑓 4 𝑆𝑦
𝑁𝑓 = 3.199
35
7.0 MASS AND COSTS
Mass Costs
Parts
(kg) (RM)
Gears 14.20 7.10
Shafts (Keys and Bearings) 4.86 2.41
Housing 20 15.00
Total 39.06 24.51
Table 2: Mass and Costs of Each Part
Hence, the total mass of the gearbox is around 39.06 kg. The raw materials cost was about RM
24.51. Including the workmanship, the total costs reach about RM 200.00.
36
8.0 DISCUSSION AND CONCLUSION
From this ‘Design of Turbine Gear-Box’ project, we have calculated a lot of parameter
to design each component of turbine gearbox such as spur gear, bearing, shaft, keys and others
by referring the method shown in the textbook.
In a turbine drive 300kW power is transmitted using pair of spur gear. The pinion speed
is 2950rpm and that of the gear is about 816.5rpm. The gear ratio is 1:3.612. The diameter and
thickness of the input gear are 5inches and 1.5inches with the amount of 135 for the number of
teeth, Ng. For the output gear (pinion), the diameter and thickness are 2inches and 1.5 inches
while the number of teeth, Ng is 37. The diametral pitch, Pd is assumed 6.
The material used for the gear is American Gear Manufacturers Association (AGMA)
A4 steel, through hardened. As for the pinion, AGMA class A5 steel, through hardened type of
material is used.
Upon the completion of this project, we manage to design the turbine gearbox which
meets the predetermined value. The design of this gearbox is all based on the source from the
textbook and internet. The material that we used and the cost that is required for this turbine
gearbox have been discussed properly and the target is to achieve the most efficiency and
desirable turbine gearbox design that we can create.
37
9.0 REFERENCES
1. Textbook:
 Machine Design, An Integrated Approach, 4th Edition
2. Internet:
 http://en.wikipedia.org/wiki/Turbine
 http://en.wikipedia.org/wiki/Transmission_(mechanics)
http://en.wikipedia.org/wiki/Accessory_drive
 http://www.motiva.fi/myllarin_tuulivoima/windpower%20web/en/tour/wtrb/powtrain.
htm
 http://machinedesign.com/article/shaft-keys-that-reduce-manufacturing-costs-and-
machine-downtime-0924
38

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UNIVERSITI TENAGA NASIONAL

MEMD314 - MACHINE DESIGN

LECTURER : MOHD RASHDAN BIN ISA

Due Date Submitted Date

3.0 Project Objective 5

6.0 Calculation of Parts 13

8.0 Discussion and Conclusion 37

1.2 Function of Product

1.3 Advantage and Disadvantage

2.0 PROJECT TITLE

Design of Turbine Gear-Box.

3.0 PROJECT OBJECTIVE

4.1 Detail Drawing

Diagram 1: Spur Gear

Diagram 1: Spur Gear

Diagram 2: Input Shaft

Diagram 3: Output Shaft

Diagram 5: Outside view of the Table Saw Gear Box

Diagram 6: Bearing, Spur Gear and Key

Diagram 7: Gearbox in Windmill turbine

Gear box specifications:

Weight : Minimal and compact

6.0 CALCULATION OF PARTS

6.1 Calculation of gear

Motor input = 300k watts

3. Output gear (pinion):-

Gear tooth specifications:

Parameter Equation , Pd = 6 values

6.1.1 Input Gear

Tmax = 31054.74 lb.in

Wtm = 15527.37 lb in /11.25 in

6.1.2 Output Gear (Pinion)

Tmax = 8595.04 lb.in

Wtmax = 2760.42 lb Wtmax = 2790.59 lb

6.1.3 Overall Gear Calculation

2. The bending stress equation for stress:

= 2276[(2760.42*1*1.6*1*1) / ( 2 ∗ 22.5 ∗ 0.79 ∗ 0.045)]^(1/2)

= [(3.08) + (1/6)) ² - (3.08 cos 25) ²] ^ 0.5 – [(𝜋/6)* cos 25]

d) Surface stress in pinion-gear mesh:

= 2276[(2790.59 *1*1.6*1*1) / ( 2 ∗ 6.16 ∗ 0.79 ∗ 0.14)]^(1/2)

4. Calculate corrected bending fatigue strength:

i) assume using AGMA class A4 steel, through hardened to 350HB

i) assume using AGMA class A5 steel, through hardened to 400HB

ii) Number of cycles:

Assume 10 year life in continuous operation.

5. Calculate corrected surface fatigue strength:

i) For an AGMA A4 steel, through hardened to 360 HB

vi) The corrected surface fatigue strength:

Sfc = ((CL.CH )/(CT.Cr))* Sfc’

i) For an AGMA A5 steel, through hardened to 400 HB

Sfc = ((CL.CH )/(CT.Cr))* Sfc’

6. Factor of safety for gear, pinion and surface gear-pinion:

= 0.047989 Mpsi / 0.03088 Mpsi

ii) FSpinion = Sfb / 𝜎 bp

iii) FSidler-gear = (Sfc / 𝜎 ci-g)²

= (0.123 Mpsi/ 0.119 Mpsi)²

iv) FSidler-pinion = (Sfc / 𝜎 ci-p)²

6.2 Calculation of Shaft

Uncorrected fatigue strength Steels

Realibility : Creliab = 0.897 (R = 90 %) Refer Table 6-4

Modified Endurance Limit:

6.2.1 Analysis of Input Shaft

1. Maximum and minimum force at input shaft

2. Maximum and minimum resultant force

= 2276[(2760.4211.611) / ( 2 ∗ 22.5 ∗ 0.79 ∗ 0.045)]^(1/2)

= 2276[(2790.59 11.611) / ( 2 ∗ 6.16 ∗ 0.79 ∗ 0.14)]^(1/2)