UNIVERSITI TENAGA NASIONAL

COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING

MEMB333 - MACHINE DESIGN

SEMESTER 2 2012/2013

PROJECT TITLE : DESIGN OF TURBINE GEAR-BOX

NAME

STUDENT ID

MOHAMAD ASYRAF BIN MOHAMAD AZMI

ME087004

MUHAMMAD FADIL ARSAD BIN MOHD USOPE

ME087018

MUHAMMAD AMIN BIN ZAKARIA

ME087006

SYARIR AKRAM BIN JAMALUDDIN

ME087022

SECTION

: 01B

LECTURER

: MUHAMMAD FAIRUZ BIN ABDUL JALAL

Due Date
30/12/2012

ABSTRACT

Submitted Date
30/12/2012

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

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, MEMB333 Machine Design. Besides that, we also
learn to develop teamwork, leadership skills, research skills, and creative thinking.
The design of the turbine gear box is basically depends on the skills of each group.
For us, this design 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.

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MEMB 333

TABLE OF CONTENT`

Content

Page
3
4
4
4
5-16
17-22
23-24
25-28
29
30
31-35
36

1.0 Introduction
2.0 Project Title
3.0 Project Objective
4.0 Specifications
5.0 Gears Calculation
6.0 Shaft Calculation
7.0 Bearing Calculation
8.0 Keys Calculation
9.0 Mass and Costs
10.0 Discussion and Conclusion
11.0 Appendices
12.0 References

1.0 INTRODUCTION

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MEMB 333

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.

Modern gearboxes mostly are used to reduce the speed of a prime mover output shaft
by increasing the torque which means that the input shaft will rotate faster than the output.
This creates mechanical advantage.

In the calculation part, we took the value of gear quality numbers, Q v based on the
application on aircraft engine drive from the Recommended AGMA Gear Quality Numbers
for Various Applications table.

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.
The completion of this project 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.

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MEMB 333

2.0 PROJECT TITLE

Design of Turbine Gear-Box.
3.0 PROJECT OBJECTIVE
To design a turbine gear-box which consists of spur gears, rolling element bearings, shafts,
keys or press fits, seals and housing.
4.0 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

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MEMB 333

5.0 GEARS CALCULATION

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

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MEMB 333

Gear tooth specifications:

Pd = 6
Therefore, coarse pitch (Pd < 20)
Parameter
Addendum a
Dedendum b
Working depth
Whole depth
Circular tooth thickness
Fillet radius-basic rack
Minimum basic clearance
Minimum width of top land
Clearance(shave or ground

Equation , Pd = 6
1.000/Pd
1.250/Pd
2.000/Pd
2.250/Pd
1.571/Pd
0.300/Pd
0.250/Pd
0.250/Pd
0.350/Pd

values
0.167
0.208
0.333
0.375
0.262
0.050
0.042
0.042
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
dp =

Np
Pd

37
6

dg =

Ng
Pd

135
6

= 6.16 in
= 22.5 in

6 is a standard pitch by referred from table 12-2, pg. 719 (Machine design textbook, 4th
Edition)
Torque:
P = T
P = 300k watts = 402.3 hp

5.1 Input Gear

[DESIGN OF TURBINE GEAR-BOX]

= 816.5 rpm =

(816.5 rpm) x 2
60

= 85.50 rad/sec

T = P/
=

6600 lb. sec

)
hp
85.50 rad /sec

( 402.3 hp ) (

= 31054.74 lb.in

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

5.2 Output Gear (Pinion)

7

MEMB 333

[DESIGN OF TURBINE GEAR-BOX]

= 2950 rpm =

(2950 rpm) x 2
60

MEMB 333

= 308.92 rad/sec

T = P/
=

6600 lb. sec

)
hp
308.92rad / sec

( 402.3 hp ) (

= 8595.04 lb.in

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

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MEMB 333

5.3 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
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
A = 50+ 56(1-B)
f) Pitch-line Velocity, Vtg = (dg/2) *g
= (22.5/2*12) (816.5 rpm *2 )
= 4809.58 ft/min
g) Pitch-line Velocity, Vtp = (dp/2) *g
= (6.16/2*12) (816.5 rpm *2 )
= 4757.42 ft/min
A
h) Velocity factor, Kvg = Cvg = A+ Vt g ] ^B

= 0.547^0.397
= 0.79
A
i) Velocity factor, Kvp = Cvp = A+ Vtp ] ^B

= 0.547^0.397
= 0.79
9

B = 0.397
A = 83.768

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MEMB 333

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 25, 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:

bg

Wt . Pd . Ka . Km . Ks . Ka . Ki
F . J . Kv

(2760.42611.6111)
20.5430.79

= 30887.9 psi
= 0.03088 Mpsi

bp

Wt . Pd . Ka . Km . Ks . Ka . Kb
F . J . Kv

(2790.59611.6111)
20.48750.79

= 34780.48 psi
= 0.035M psi

10

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MEMB 333

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
Surface factor, Cf = 1

(From equation 12.23)

(Well finished gear by conventional method)

b) The surface geometry factor I can be calculated:

Gear (Idle)
1 = ((rg + (1/Pd) - (rg cos )) ^ (1/2) (( /Pd *cos )
= [(11.25) + (1/6)) - (11.25 cos 25) ] ^ 0.5 [( /6)* cos 25]
= 4.7
2 = C sin

- 1

= (rp + rg) sin

- 1

= (3.08 + 11.25) sin 25 4.7

= 1.42
1/

I = (cos

1 + 1/2)*

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
cig = Cp(

= 2276[

Wt . Ca. Cm .Cs . Cf ( 2 )
)
F .dg .Cv . I

2760.42
(1 /2)
*1*1.6*1*1) / ( 222.50.790.045

= 119589.69 psi
= 0.119 Mpsi
11

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MEMB 333

Pinion (Idle)
1 = ((rp + (1/Pd) - (rp cos )) ^ (1/2) (( /Pd *cos )
= [(3.08) + (1/6)) - (3.08 cos 25) ] ^ 0.5 [( /6)* cos 25]
= 1.183
2 = C sin

- 1

= (rp + rg) sin

- 1

= (3.08 + 11.25) sin 25 1.183

= 4.87
I = (cos

1/

1 + 1/2)*

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
cip = Cp(

= 2276[

Wt . Ca. Cm .Cs . Cf ( 2 )
)
F .dp . Cv . I

2790.59
(1/ 2)
*1*1.6*1*1) / ( 26.160.790.14

= 130285.87 psi
= 0.130 Mpsi

12

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MEMB 333

4. Calculate corrected bending fatigue strength:

For gear
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

13

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MEMB 333

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:

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

14

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MEMB 333

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:

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
15

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MEMB 333

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 / bg
= 0.047989 Mpsi / 0.03088 Mpsi
Nb gear = 1.55
ii) FSpinion = Sfb / bp
= 0.051981Mpsi / 0.034780M psi
Nb pinion = 1.5
iii) FSidler-gear = (Sfc / ci-g)
= (0.123 Mpsi/ 0.119 Mpsi)
Nc idler-gear = 1.1
iv) FSidler-pinion = (Sfc / ci-p)
= (0.1382 Mpsi/ 0.130285 Mpsi)
Nc idler-gear = 1.13

16

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MEMB 333

6.0 SHAFT CALCULATION

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
Size
Surface

:
:

Cload = 1
Csize = 1
:
Refer Table 6-3: A = 2.7
b = -0.265

(bending load)

(machined cold

rolled)
Temperature :
Realibility
:

Csurface = A. (Sut)b = 2.7 ( 64 )-0.265 = 0.84

Ctemp = 1
Creliab = 0.897
(R = 90 %) Refer Table 6-4

Modified Endurance Limit:

Sf = Cload . Csize . Csurf . Ctemp . Creliab . Sf
= 24111.36 kpsi
17

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MEMB 333

6.1 Analysis of Input Shaft

1. Maximum and minimum force at input shaft
Ft =
max

T max
rg

Where T max is the maximum torque exert on the input shaft through gear which gives
Ft

= 186.434 lb

max

Where, minimum force at input shaft is 0 lb because the minimum force is 0.

2. Maximum and minimum resultant force
Fmax =
Ft

Where

max

Ft
186.434
=
cos cos ( 20)
max

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.
M max=

l x F max
4

M max=

(4 x 198.399)
=198.399 lb .
4

Where minimum moment is zero because

4. Finding

M mean and

M m=

M max + M min
2

M a=

M maxM min
2

M m=M a=

Fmin

M alternating

198.3990
2
18

is 0.

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MEMB 333

M m=M a=99.1995lb .

5. Finding T m and T a
T m=
T a=

T max + T min
2

T max T min
2

T a=T m=

186.4340
2

T a=T m=93.217 lb .
6. Calculating uncorrected endurance strength, S
S =0.5 Sut
S =0.5(64000)
S =32000 psi
Where the material used is SAE 1018 cold-rolled steel with S ut

= 64 kpsi and

kpsi gives S =32000 psi

C surf Ctemp Creliab S
S e=C load C
Where: -

Cload =1 for bendingtorsion ,

1 since we dont know t h e

C

C surf =0.84 , Ctemp =1 since no temperature given ,

Creliab =0.897 for 90 reliability .
S e =( 1 ) (1 )( 0.84 )( 1 ) ( 0.897 ) (32000)
S e =24111.36 psi
7. Finding bending and torsional stress in the keyway
K f =1+q ( K t1)

19

Sy

= 54

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MEMB 333

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
K f =1+q ( K t1)
K f =1+0.5 ( 3.01 )
K f =K fm=2.00
K f =1+q ( K t1)
K f =1+0.57 ( 3.01 )
K fs =K fsm=2.15
8. Finding input diameter
N sf =2.5

Assume

( kf M a)

3
2+ (k fs T a )2
4
2 3
2
k fm M m ) + ( k fsm T m )
(
(
)
4
+
Sf
S ut

1
3

32 N sf

d input =

2
( (99.1995) )

3
2+ ((2.15)(93.217))2
4

2 3
2
( ( (99.1995) ) ) + ((2.15)(93.217) ) )
(2
4

+
24111.36
64000

32( 2.5)

dinput =
d input = 0.6872 in
20

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MEMB 333

6.2 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 :
T m=
T a=

T max + T min
2

T max T min
2

T a=T m=

186.4340
2

Ta=Tm=93.217 lb.

x 40% = 37.2868 lb.

2. Finding output diameter

21

[DESIGN OF TURBINE GEAR-BOX]

( kf M a)

3
2+ (k fs T a )2
4
2 3
2
k fm M m ) + ( k fsm T m )
(
(
)
4
+
Sf
S ut

1
3

32 N sf

d output =

2
( ( 99.1995) )

3
2+ (( 2.15)(37.2868))2
4

( 99.1995() )

3
2
2+ ((2.15)(37.2868) )
4
64000

32(2.5)

d output =

d output = 0.6105 in

22

MEMB 333

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MEMB 333

6.3 Analysis of Shaft Deflection

1. Input shaft (deflection)
Angular deflection in
=

(radian)

Tl
GJ
4

Where, J for solid shaft is J =

d
32

( 0.6872 )
32

( 0.6105 )
32

= 0.0219 4

l = length of shaft

T= torque experience at shaft

G for steel carbon = 11.7Mpsi
Therefore,
=

(93.217)(4)
(0.0219)(11.7 M )

=1.455 x 103 4
6.3.3.2 Output shaft (deflection)
4

Where, J for solid shaft is J =

d
32

(37.2868)(4)
( 0.0136)(11.7 M )
4

=9.373 x 10

23

= 0.0136

[DESIGN OF TURBINE GEAR-BOX]

7.0 BEARING CALCULATION

1.

Input bearing:

d shaft =0.6872
bearing number=6304
C=3000 lb

C o=1930 lb
P=

T
186.434
=
=46.6085lb
Lshaft
4

K R =0.21( Reliability 99 )
Co
P

1930
46.6085

L10=
3

LP =K R L10=0.21(71.003 x 10 )=14.911 x 10 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

24

MEMB 333

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2. Output bearing:
d shaft =0.6105
bearing number =6303
C=2320 lb

C o=1460 lb
P=

T
93.217
=
=23.3043 lb
Lshaft
4

K R =0.21( Reliability 99 )
Co
P

1460
23.3043

L10=
LP =K R L10=0.21(2.459 x 10 5)=5.164 x 104 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
25

MEMB 333

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

8.0 KEYS CALCULATION

1. 1st Shaft (gear shaft)
Mean torque = 93.217 lb. in

Diameter = 0.6872 in

Alternating torque = 93.217 lb. in

Fm =

Fa=

Ta 93.217
=
=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:
a=
m=

Fa
271.295
=
= 2901.55 psi
A s h ear ( 0.187 ) (0.5)

Fm
271.295
=
=2901.55 psi
A s h ear ( 0.187 ) (0.5)

Von Mises equivalent stresses for each component:

' a= x 2 + y 2 x 2 y 2 +3 2 xy= 3(2901.55)=4103.411 psi

' m= x2 + y 2 x 2 y2 +3 2 xy= 3(2901.55) =4103.411 psi

From this we achieved the fatigue safety factor:
26

[DESIGN OF TURBINE GEAR-BOX]

Nf

1
'a 'm
+
Se Sut

1
4103.411 4103.411
+
24111.36
64000

MEMB 333

4.268

Maximum force of the key

' max=

Fm+ Fa 271.295+271.295
=
=8681.44 psi
A bearing
0.125(0.5)

Safety factor for bearing failure

Ns=

Sy
54000
=
=6.22
max 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
K t=2.5
K ts=2.7

K f =1+q ( K t1) ; Where

q=

1
1+

a
r

= 0.5 (bending)

Kf = 1.75
K ts 1
)
K fs =1+q
K fs =1+0.5 ( 2.71 )=1.8 5
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[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

K fsm =K fs= 1.85

{ [(

32 Nf
d 1=

Ma 2 3
Tm
Kf
+ K fsm
Sf
4
Sy

) (

1/ 3
2 1 /2

)]

Nf = 4.13

2. 2nd Shaft (pinion shaft)

Mean torque = 37.287 lb. in

Diameter = 0.6105 inch

Alternating torque = 37.287 lb. in

Fa=

Ta 37.287
=
=122.152lb
r 0.30525
Fm=

Tm 37.287
=
=122.152 lb
r 0.30525

Assumption X inch of the alternating and mean shear stress components

Assumed key length 0.5 = inch:
a=

Fa
122.152
=
= 1306.439 psi
A s h ear ( 0.187 ) (0.5)

0.187

0.5
()

Fm
122.152
m=
=

A s h ear
Von Mises equivalent stresses for each component;
' a= x 2 + y 2 x 2 y 2 +3 2 xy= 3(1306.439)=2262.819 psi

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[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

' m= x2 + y 2 x 2 y2 +3 2 xy= 3(1306.439)=2262.819 psi

From this we achieved the fatigue safety factor:

Nf

'a 'm
+
Se Sut

1
2262.819 2262.819
+
24111.36
64000

7.74

Maximum force of the key

max =

Fm+ Fa 122.152+ 122.152

=
=3908.864 psi
A bearing
( 0.125 ) (0.5)

Safety factor for bearing failure

Ns=

Sy
54000
=
=13.815
max 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
K t=2.35
K ts=2.75
K f =1+q ( K t1) ; Where

q=

1
1+

a
r

= 0.5 (bending)

Kf = 1.675

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[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

K ts 1
)
K fs =1+q
K fs =1+0.5 ( 2.751 )=1.875
K fsm =K fs= 1.875

{ [(

32 Nf
d 2=

Ma 2 3
Tm
Kf
+ K fsm
Sf
4
Sy

) (

1/ 3
2 1 /2

)]

Nf = 3.199

9.0 MASS AND COSTS

Mass

Costs

Gears

(kg)
14.20

(RM)
7.10

Shafts (Keys and Bearings)

4.86

2.41

Housing

20

15.00

Tot a l

39.06

24.51

Parts

Tab l e 2 : M a s s a n d C o s t s o f E a c h P a r t
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.

30

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

10.0 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 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
31

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

turbine gearbox have been discussed properly and the target is to achieve the most efficiency
and desirable turbine gearbox design that we can create.

11.0 APPENDICES
Project Drawing:

Diagram 1:Spur Gear

32

[DESIGN OF TURBINE GEAR-BOX]

Diagram 2:Input Shaft

Diagram 3: Output Shaft

33

MEMB 333

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

Diagram 4: Pinion 1

Diagram 5: Outside view of the Table Saw Gear Box

34

[DESIGN OF TURBINE GEAR-BOX]

Diagram 6: Bearing, Spur Gear and Key

35

MEMB 333

[DESIGN OF TURBINE GEAR-BOX]

Diagram 7: Gearbox in Windmill turbine

36

MEMB 333

[DESIGN OF TURBINE GEAR-BOX]

MEMB 333

12.0 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-andmachine-downtime-0924

37